Download Carrier PC211 Specifications

23XL
Hermetic Screw Liquid Chillers with HCFC-22
and HFC-134a, 50/60 Hertz
PIC II Controls
Start-Up, Operation and Maintenance
Instructions
SAFETY CONSIDERATIONS
Screw liquid chillers are designed to provide safe and
reliable service when operated within design specifications. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
property or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions, as
well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American
National Standards Institute, American Society of Heating, Refrigeration, and Air Conditioning Engineers), latest edition. The accumulation of refrigerant in an enclosed space can displace oxygen and cause
asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart
irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is
heavier than air and reduces the amount of oxygen available for
breathing. Product causes eye and skin irritation. Decomposition
products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for
any purpose. Oxygen gas reacts violently with oil, grease, and other
common substances.
NEVER EXCEED specified test pressures. VERIFY the allowable
test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller.
Traces of vapor should be displaced with dry air or nitrogen and the
work area should be well ventilated. Refrigerant in contact with an
open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the
entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including control centers, switches, starters, or oil heater (if applicable) until you are sure
ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
DO NOT syphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar, and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than those cited
herein should comply with ANSI/ASHRAE 15 (latest edition). Contact Carrier for further information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sure pressure is
at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the starter, tower fan, or pumps. Shut off the
chiller or pump before servicing equipment.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids without the permission of your process
control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
other items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Catalog No. 532-306
Printed in U.S.A.
Form 23XL-3SS
Pg 1
7-99
Replaces: New
Tab 5e
CONTENTS
Page
Oil Sump Temperature Control TC
(Frame 1 and 2) Chillers Only . . . . . . . . . . . . . . . . . 39
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 40
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Spare Safety Alarm Contacts . . . . . . . . . . . . . . . . . . . . 40
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 40
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 40
Condenser Freeze Protection. . . . . . . . . . . . . . . . . . . . 40
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 40
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 41
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 41
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 41
• HEAD PRESSURE OUTPUT REFERENCE
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• COMMON POINT SENSOR INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
• ICE BUILD INITIATION
• START-UP/RECYCLE OPERATION
• TEMPERATURE CONTROL DURING ICE BUILD
• TERMINATION OF ICE BUILD
• RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . . . . 45
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 48
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 49
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 49-65
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 49
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 49
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . . . 49
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 49
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chiller Dehydration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 59
Check Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• MECHANICAL STARTER
• BENSHAW, INC. REDISTART MICRO
SOLID-STATE STARTER
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 5
23XL CHILLER FAMILIARIZATION . . . . . . . . . . . . . . 5-8
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Muffler-Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Factory-Mounted Starter (Optional Accessory) . . . 8
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8
MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
• TC FRAME 1 AND 2 CHILLERS
• TD FRAME 4 CHILLERS
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
• TC FRAME 1 AND 2 CHILLERS
• TD FRAME 4 CHILLERS
Oil Loss Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Slide Valve Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 12,13
Unit Mounted Solid-State Starter (Optional) . . . . . 13
Unit Mounted Wye-Delta Starter (Optional) . . . . . . 13
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
• ANALOG SIGNAL
• DIGITAL SIGNAL
General Controls Overview . . . . . . . . . . . . . . . . . . . . . . 14
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 14
• CHILLER VISUAL CONTROLLER (CVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• CONTROL TRANSFORMERS (T1, T2)
CVC Operation and Menus . . . . . . . . . . . . . . . . . . . . . . 19
• GENERAL
• ALARMS AND ALERTS
• CVC MENU ITEMS
• BASIC CVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 37
• CAPACITY CONTROL
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• CHILLER TIMERS
• OCCUPANCY SCHEDULE
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Low Discharge Temperature Control . . . . . . . . . . . . 39
2
CONTENTS (cont)
Page
Operating the Optional Pumpout Unit . . . . . . . . . . . 69
• TO READ REFRIGERANT PRESSURES
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70
• TRANSFER ALL REFRIGERANT TO CHILLER
CONDENSER VESSEL
• TRANSFER ALL REFRIGERANT TO CHILLER
COOLER VESSEL
• RETURN CHILLER TO NORMAL OPERATING
CONDITIONS
Chillers With Storage Tanks . . . . . . . . . . . . . . . . . . . . . 71
• TRANSFER REFRIGERNT FROM PUMPOUT
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 72
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test After Service, Repair, or Major Leak . . . . . . . . 72
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 73
Check the Lubrication System . . . . . . . . . . . . . . . . . . 73
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-76
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Separator Coalescer . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Strainers (TC Frame 1 and
2 Chillers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 74
Compressor Bearing Maintenance . . . . . . . . . . . . . . 75
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 75
• COOLER
• CONDENSER
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment . . . . . . . . . . . . . . . . . 75
Check Pressure Transducers. . . . . . . . . . . . . . . . . . . . 76
Optional Pumpout System Maintenance. . . . . . . . . 76
• OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 76
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-103
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the Display Messages. . . . . . . . . . . . . . . . . 77
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 77
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Page
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 60
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 60
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input Service Configurations . . . . . . . . . . . . . . . . . . . . 60
• PASSWORD
• INPUT TIME AND DATE
• CHANGE CVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE CVC DISPLAY FROM ENGLISH
TO METRIC UNITS
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform A Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• COOLER AND CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 64
• CHILLER EQUALIZATION WITHOUT
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65,66
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65
Check Oil Pressure and Compressor Stop . . . . . . 65
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 66
Check Chiller Operating Condition . . . . . . . . . . . . . . 66
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 66
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP OPERATION,
AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 66-68
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 67
Preparation for Extended Shutdown . . . . . . . . . . . . 67
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Slide Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3
CONTENTS (cont)
INTRODUCTION
Page
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 77
• COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 78
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 88
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 89
• INPUTS
• OUTPUTS
Integrated Starter Module (ISM) . . . . . . . . . . . . . . . . . 89
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . . 89
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC., SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INITIAL START-UP CHECKLIST FOR
23XL HERMETIC SCREW
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12
Prior to initial start-up of the 23XL chiller, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the startup, operation and maintenance of the unit with the control system before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules. Control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center.
Use extreme care when handling tools near circuit boards
and when connecting or disconnecting terminal plugs.
Circuit boards can be damaged easily. Always hold boards
by the edges, and avoid touching components and
connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may interfere with radio communications. This equipment has been tested and found to comply
with the limits for a Class A computing device pursuant to
Subpart J of Part 15 of FCC Rules, which are designed to
provide reasonable protection against such interference
when operated in a commercial environment. Operation of
this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be
required to take whatever measures may be required to correct the interference.
Always store and transport replacement or defective boards
in an anti-static shipping bag.
4
ABBREVIATIONS AND EXPLANATIONS
23XL CHILLER FAMILIARIZATION
(Fig. 1, 2A, and 2B)
Frequently used abbreviations in this manual include:
CCM
— Chiller Control Module
CCN
— Carrier Comfort Network
CVC
— Chiller Visual Controller
CCW
— Counterclockwise
CW
— Clockwise
ECDW — Entering Condenser Water
ECW
— Entering Chilled Water
EMS
— Energy Management System
HGBP
— Hot Gas Bypass
I/O
— Input/Output
ISM
— Integrated Starter Module
LCD
— Liquid Crystal Display
LCDW — Leaving Condenser Water
LCW
— Leaving Chilled Water
LED
— Light-Emitting Diode
OLTA
— Overload Trip Amps
PIC II
— Product Integrated Control II
RLA
— Rated Load Amps
SCR
— Silicon Controlled Rectifier
SI
— International System of Units
Chiller Identification Nameplate — The chiller
identification nameplate is located on the right side of the
chiller control panel center.
System Components — The components include
cooler and condenser, heat exchangers in separate vessels,
motor-compressor, lubrication system, control panel, and
optional motor starter. All connections from pressure vessels
have external threads to enable each component to be pressure
tested with a threaded pipe cap during factory assembly.
23XL
21
21
Model Description
Hermetic Screw
Liquid Chiller
C6
0
1 — Variable V I
0 — Fixed V I
Compressor Size
C2 — 1260 Tons
(560 kW)
C4 — 200 Tons
(700 kW)
C6 — 250 Tons
(880 kW)
D4 — 300 Tons
(1055 kW)
D6 — 350 Tons
(1230 kW)
Cooler Size
10,11 — TC Frame 1
20, 21 — TC Frame 2
40,41,42,43 — TD Frame 4
Condenser Size
10,11 — TC Frame 1
20,21 — TC Frame 2
40,41,42,43 — TD Frame 4
Words printed in all capital letters or in italics may be
viewed on the Chiller Visual Controller (CVC) (e.g., LOCAL,
CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also
be viewed on the CVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, ICE BUILD
OPTION, etc.) with associated values (e.g., modes, temperatures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the CVC control panel (e.g., ENTER , EXIT ,
INCREASE , QUIT , etc.).
E
E — Economizer
N — No Economizer
99
Year of Manufacture
Week of Year
28
J
59743
Unique Number
Place of Manufacture
LEGEND
VI — Volumetric Index
SERIAL NUMBER BREAKDOWN
Fig. 1 — 23XL Identification
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed additional components are referred to as accessories.
The chiller software part number of the 23XL unit is located
on the back of the CVC.
5
FRONT VIEW
12
1
1
2
3
4
5
6
7
8
9
10
11
12
2
11
10
9
—
—
—
—
—
—
—
—
—
—
—
—
Power Panel
Chiller Visual Controller (CVC)
Cooler Refrigerant Isolation Valve
ASME Nameplate, Economizer (Hidden)
Service Valve
Take-Apart Rabbet Fit Connector (Lower)
Cooler Temperature Sensor
ASME Nameplate, Condenser/Cooler
Typical Waterbox Drain Port
Cooler Supply/Return End Waterbox Cover
Condenser Supply/Return End Waterbox Cover
Compressor Nameplate (Hidden)
8
7
6
5
3
4
REAR VIEW
13
14
27
15
26
5
16
10
25
13
14
15
16
17
18
19
20
21
—
—
—
—
—
—
—
—
—
22
23
24
25
—
—
—
—
17
18
7
26 —
27 —
9
Oil Separator
ASME Nameplate, Muffler (Hidden)
ASME Nameplate, Oil Separator
Cooler Relief Valves (Hidden)
Oil Sump Filter Assembly
Oil Charging Valve
Vessel Separation Feet
Float Chamber
Condenser Isolation Valve
(Option or Accessory)
Refrigerant Charging Valve
Condenser
Condenser Relief Valves (Hidden)
Take-Apart Rabbet Fit Connector
(Upper)
Unit Mounted Starter (Option)
Machine Identification Nameplate
11
5
24
23 22
21 20
19
Fig. 2A — Typical 23XL Installation (TC Frame 1 and 2 Chillers)
6
FRONT VIEW
1
2
1
2
3
4
5
6
7
—
—
—
—
—
—
—
8
9
10
11
12
13
14
15
—
—
—
—
—
—
—
—
3
4
18
5
17
16
15
14
16 —
17 —
18 —
13
12
11
10
7
8
9
Compressor Nameplate (Hidden)
Power Panel
Chiller Visual Controller (CVC)
ASME Nameplate, Cooler
Cooler
Vessel Separation Feet
Economizer Float Valve Access Cover
(Hidden)
Refrigerant Charging Valve
Economizer
Oil Filter Assembly (Hidden)
ASME Nameplate, Economizer
Typical Waterbox Drain Port
Take-Apart Rabbet Fit Connector
ASME Nameplate, Condenser/Cooler
Cooler Supply/Return End Waterbox
Cover
Condenser Temperature Sensors
Condenser Water Pressure Sensors
Cooler Relief Valve
6
REAR VIEW
19
20
22
21
23
35
34
24
25
33
19
20
21
22
23
24
—
—
—
—
—
—
25
26
27
28
29
30
31
32
—
—
—
—
—
—
—
—
33
34
35
—
—
—
32
12
31
30
29
28 27
8
Unit Mounted Starter (option)
ASME Nameplate, Oil Separator
Oil Separator Relief Valves
Oil Separator
Oil Charging Valve
Condenser Isolation Valve (Option or
Accessory)
Service Valve
Cooler Refrigerant Isolation Valve
Condenser Relief Valves and Oil Filter
Float Chamber
Poppet Valve Assembly
Motor Cooling Isolation Valve
Condenser
Condenser Supply/Return End
Waterbox Cover
Cooler Temperature Sensors
Cooler Water Pressure Sensors
Machine Identification Nameplate
26
Fig. 2B — Typical 23XL Installation (TD Frame 4 Chiller)
7
Cooler — This vessel (also known as the evaporator) is
Relatively cool (typically 65 to 85 F [18 to 29 C]) water
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 3 and 4). Since the
FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid.
The FLASC vapor is recondensed on the tubes which are
cooled by entering condenser water. The liquid then passes
through a float valve assembly which forms a liquid seal to
keep FLASC chamber vapor from entering the cooler.
An optional economizer can be installed between the condenser and cooler. In this case, the float valve meters the refrigerant liquid into the economizer. Pressure in this chamber is intermediate between condenser and cooler pressures. At this
lower pressure, some of the liquid refrigerant flashes to gas,
cooling the remaining liquid. The flash gas, having absorbed
heat, is returned directly to the compressor at a point after suction cutoff (Fig. 5). Here it is mixed with gas from the suction
cut-off point to produce an increase in the mass flow of refrigerant transported and compressed without either an increase in
suction volume or a change in suction temperature. Rather than
providing the same capacity with less power, the compressor
provides substantially increased capacity with only a slight increase in power requirements.
The cooled liquid refrigerant in the economizer is metered
through a linear float valve into the cooler. Because pressure in
the cooler is lower than economizer pressure, some of the liquid flashes and cools the remainder to evaporator (cooler) temperature. The cycle is now complete.
located underneath the compressor. The cooler is maintained at
low temperature/pressure so that evaporating refrigerant can
remove heat from water/brine flowing through its internal
tubes.
Condenser — The condenser operates at a higher
temperature/pressure than the cooler and has water flowing
through its internal tubes to remove heat from the refrigerant.
Motor-Compressor — The motor-compressor maintains system temperature/pressure differences and moves the
heat carrying refrigerant from the cooler to the condenser.
Muffler-Oil Separator — The muffler provides acoustical attenuation.
Refrigerant/oil separation is accomplished by the oil separator. Discharge gas enters near the midsection and leaves near
the top, while the separated oil drains out through the bottom
and flows through a horizontal oil sump/filter assembly (TC
frame 1 and 2 chillers).
TC frame 1 and 2 chillers have an oil separator and a muffler assembly. On TD frame 4 chiller, the muffler is located inside the oil separator.
Control Panel — The control panel is the user interface
for controlling the chiller and regulating the chiller’s capacity
to maintain the proper chilled water temperature. The control
panel:
• registers cooler, condenser, and lubricating system
pressures
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours, starts, and the
number of hours the chiller has been currently running
• sequences chiller start, stop, and recycle under microprocessor control
• provides access to other Carrier Comfort Network
devices
MOTOR COOLING CYCLE
The motor is cooled by liquid refrigerant taken from the
bottom of the condenser vessel. The flow of refrigerant is
maintained by the pressure differential that exists due to compressor operation. The refrigerant flows through an isolation
valve, in-line filter/drier, and a sight glass/moisture indicator
(dry-eye), into the motor through the motor spray nozzle. See
Fig. 3 and 4.
The motor spray nozzle is orificed to control refrigerant
flow through the gaps in the rotor and axial vent holes. The refrigerant collects in the bottom of the motor casing and then
drains into the cooler through the motor cooling drain line.
The motor is protected by a temperature sensor imbedded
in the stator windings. Motor temperatures above the MOTOR
WINDING TEMPERATURE OVERRIDE THRESHOLD
(see Capacity Override section, page 38) will override the
chilled water temperature capacity control to hold. If the motor
temperature rises 10 F (5.5 C) above this threshold, the slide
valve will unload. If the motor temperature rises above the
safety limit, the compressor will shut down.
Factory-Mounted Starter (Optional Accessory) — The starter allows for the proper starting and disconnecting of electrical energy for the compressor-motor, oil
heater (TC frame 1 and 2 chillers), and control panel.
Storage Vessel (Optional) — Two sizes of storage
vessels are available. The vessels have double relief valves,
a magnetically coupled dial-type refrigerant level gage, a
1-in. FPT drain valve, and a 1/2-in. male flare vapor connection
for the pumpout unit. A 30-in.-0-400 psi (–101-0-2750 kPa)
gage is also supplied with each unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled optional isolation valves may be used to isolate the
chiller charge in either the cooler or condenser. An optional
pumpout compressor system is used to transfer refrigerant
from vessel to vessel.
LUBRICATION CYCLE
REFRIGERATION CYCLE
Summary — The 23XL does not require an oil pump. Oil
flow is driven by differential pressure between condenser and
evaporator. This system pressure difference holds the potential
to push the oil through the oil separator and filter into the compressor rotors, bearings, and slide valve. The cycle is referred
to as a “high side” oil system. See Fig. 3, 4, and 5.
The compressor continuously draws refrigerant vapor from
the cooler. As the compressor suction reduces the pressure in
the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required
for boiling is obtained from the water flowing through the cooler tubes. With heat energy removed, the water becomes cold
enough for use in an air-conditioning circuit or process liquid
cooling.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more energy, and the refrigerant is quite warm (typically 130 to 160 F [54 to 71 C])
when it is discharged from compressor into condenser.
Details — The oil system:
•
•
8
lubricates the roller bearings which support the male
and female rotors, and the ball bearings of the 23XL
compressor.
positions the slide valve for capacity control. The slide
valve is connected to a piston via a rod. The position of
the piston, which rides in a cylinder, is determined by
energizing one of two solenoids which function to
(TC frame 1 and 2 chillers), and oil filter. Oil temperature is
measured and displayed on the CVC default screen. During
shutdown, oil temperature is maintained by the Product Integrated Control II (PIC) II). See Oil Sump Temperature Control
section on page 39.
NOTE: TD frame 4 chillers do not have an oil heater.
Operating oil pressure must be at least 20 psi (138 kPa) for
HCFC-22 [7 psi (48.3 kPa) for HFC-134a] and is dependent
upon system pressure differential (lift). The oil pressure transducer is located downstream of the filter, so the value displayed
on the CVC will be slightly less than the lift value. Under normal full load conditions, oil pressure is approximately 120 psi
(827 kPa) [76 psi (517 kPa)]. If sufficient system differential
pressure is not established or maintained, oil pressure will not
be established (or will be lost) and chiller shutdown will result.
The compressor provides a pressure differential, but the system pressure differential is constrained by the temperatures of
the chilled and tower water circuits. Cold tower water, rapid
tower water temperature swings, and high return chilled water
temperature are among the factors which could contribute to
frequent low oil pressure alarms. To help ensure that suitable
oil pressure is established at start-up, sufficient tower water
control should exist. Increasing the chiller ramp loading rate
will allow faster compressor load up. This will quickly establish the refrigerant and, therefore, oil pressure differential.
Conversely, rapid loading of the compressor could cause
any refrigerant in the oil to flash due to the sudden drop in suction pressure. During initial start-up, the 23XL PIC II control
follows a ramped oil pressure requirement algorithm for the
first 160 seconds. Therefore, the PIC II control follows and internal oil pressure ramp loading schedule during initial start-up.
See The Troubleshooting Guide section on page 76 for further
information.
If the start-up oil pressure falls below the values specified in
Table 1, the PIC II control will shut down the chiller.
supply and equalize oil pressure to and around the piston. This allows the slide valve to unload and load.
• seals the gap between the male and female rotors. The
oil hydrodynamically seals this space to allow the refrigerant vapor to be compressed. A specific flow rate of oil
is injected into the compressor rotor housing at the point
where the compression process is initiated.
• cools the compressed refrigerant vapor. The oil that is
injected into the compressor for sealing also acts as a
heat sink by absorbing a portion of the heat from compression. Thus, constant and cool compressor discharge
gas temperature, relative to an oil-less screw compressor, is maintained.
Oil is charged into the system through a hand valve located
on the bottom of the oil sump (TC frame 1 and 2 chillers) or
separator (TD frame 4 chillers). Sight glasses on the oil sump
(TC frame 1 and 2 chillers) and/or oil separator (TD frame 4
chillers) permit oil level observation. When the compressor is
shut down, an oil level should be visible in the oil sump (TC
frame 1 and 2 chillers) or the lower oil separator sight glass
(TD frame 4 chillers). During operation, the oil level should
rise and be visible in the oil separator sight glass (TC frame 1
and 2 chillers) or the upper oil separator sight glass (TD frame
4 chillers). Approximately 4.2 gal. (15.9 L) of an oil and refrigerant mixture accumulates in the sump of TC frame 1 and 2
chillers. Approximately 10 gal (38 L) of oil accumulates in the
separator and 2 gal. (7.6 L) accumulates on the cooler of TD
frame 4 chillers.
Oil is driven from the oil separator through an oil filter to
remove foreign particles. The oil filter has a replaceable cartridge. The filter housing is capable of being valved off to permit removal of the filter (see Maintenance sections, pages 7276, for details). The oil then travels through a shutdown solenoid and past a pressure transducer to three separate inlets on
the compressor. The oil pressure measured by the transducer is
used to determine the oil pressure differential and pressure drop
across the oil filter. The oil pressure differential is equal to the
difference between the oil pressure transducer reading and the
evaporator pressure transducer reading. It is read directly from
the Chiller Visual Controller (CVC) default screen.
Part of the oil flow to the compressor is directed to the slide
valve and is used for capacity control positioning. The remaining oil flow is divided between the rotors and bearings. A specific quantity is sent to the rotors and injected at the start of
compression to seal the clearances between the rotors. Another
portion is sent to the bearings and used for lubrication.
Oil leaves the compressor mixed with the compressed discharge refrigerant vapor. The mixture then enters the oil separator, where oil is removed from the refrigerant and collected at
the bottom to complete the cycle.
TC FRAME 1 AND 2 CHILLERS — The oil and refrigerant
vapor mixture enters the oil separator through a nearly tangential nozzle, giving a rotational flow pattern. Oil is thrown to the
sides of the oil separator and runs down the walls to a chamber
in the bottom where it drains to the sump. A baffle separates
this chamber from the vortex flow to prevent re-entrainment.
Gas flows up through a vortex funnel to a removable coalescing element where the rest of the oil collects. This oil runs
down the element surface to a scavenge line which is piped to
the first closed lobe port.
TD FRAME 4 CHILLERS — The oil and refrigerant vapor
mixture is directed against the rear wall of the oil separator as it
enters the side of the oil separator. This action causes the bulk
of the oil to drop from the refrigerant and collect at the bottom
of the oil separator. A mesh screen is provided near the oil separator outlet to remove any additional oil which may still be entrained in the refrigerant vapor.
The oil sump (TC frame 1 and 2 chillers) contains a combined level switch and temperature sensor, 500-watt oil heater
Table 1 — Oil Pressure Ramp-Up Rate
TIME
(SEC)
40
80
120
MINIMUM START-UP OIL PRESSURE
REQUIREMENT
HCFC-22
HFC-134a
psi
kPa
psi
kPa
1.4
9.7
1.4
9.7
4
27.6
4
27.6
7
48.3
7
48.3
Oil Reclaim System — The oil reclaim system operates
to return oil from the cooler back to the compressor.
TC FRAME 1 AND 2 CHILLERS — The oil reclaim system returns oil to the compressor using discharge gas pressure
to power an ejector. The oil and refrigerant mixture is vacuumed from the top of the cooler liquid refrigerant level and discharged into the compressor suction port.
TD FRAME 4 CHILLERS — TD frame 4 chillers do not require an external oil reclaim system.
Oil Loss Prevention — The suction pan is located on
top of the cooler, where oil collects during low-load operation.
The cooler is designed so that when oil drains into the cooler
from the compressor during low loads, it will be re-entrained
with the suction gas flow.
In addition, the PIC II Controls minimize oil loss to the
cooler once the rotor inlet temperature sensor detects hot oil
draining down the suction pipe.
If the rotor inlet temperature increases 4 F (2.2 C) in TC
(frame 1 and 2) chillers or TD (frame 4) chillers above the
leaving chilled water temperature, the slide valve is proportionately moved in the load direction to increase suction gas velocity. The chiller will continue to load until the rotor inlet temperature is equal to LCWT+1° F or the chiller recycles.
9
10
HGBP
LEGEND
— Hot Gas Bypass
Refrigerant Liquid Flow
Refrigerant Vapor Flow
Oil and Refrigerant Liquid Flow
Oil and Refrigerant Vapor Flow
Oil Flow
Fig. 3 — Refrigerant Oil Flow Schematic (TC Frame 1 and 2 Chillers)
11
HGBP
LEGEND
— Hot Gas Bypass
Refrigerant Liquid Flow
Refrigerant Vapor Flow
Oil and Refrigerant Vapor Flow
Oil Flow
Fig. 4 — Refrigerant Oil Flow Schematic (TD Frame 4 Chillers)
Fig. 5 — Screw Compressor Principle
Fig. 6 — Slide Valve Position at Unload
TO SUCTION PORT
Slide Valve Principle — Oil flow to the slide piston is
controlled by two solenoid valves. Each solenoid is operated
by load and unload signals from the PIC II control.
To unload the compressor, the unload solenoid valve is energized and the load solenoid valve is deenergized. This conducts high pressure oil to the cylinder, retracting the capacity
rod, and modulating the slide valve toward the open position.
See Fig. 6. The slide valve opening vents compressed gas back
to the suction port on the compressor, retarding the start of the
compression process.
To load the compressor, the unload solenoid valve is deenergized and the load solenoid valve is energized. This bleeds oil
from the cylinder to the suction pressure area within the compressor housing. Forces resulting from the discharge-to-suction
pressure differential are then allowed to push the slide valve toward the closed (fully loaded) position. See Fig. 7. When the
slide valve is closed, the compressor pumps the maximum gas
flow.
Extension and retraction of the piston/capacity rod position
the slide valve along the bottom of the rotors. The valve position controls the gas flow rate delivered by the compressor.
UNLOAD
LOAD
SOLENOID SOLENOID
VALVE
VALVE
HIGH
PRESSURE
OIL
ROTOR
PISTON
SLIDE VALVE
Fig. 7 — Slide Valve Position at Full Load
Circuit breaker CB2 supplies power to the control panel, TC
frame 1 and 2 chillers, oil heater, and portions of the starter
controls.
An optional circuit breaker is available when required for a
pumpout unit.
STARTING EQUIPMENT
The 23XL requires a motor starter to operate the centrifugal
hermetic compressor motor and various auxiliary equipment.
The starter is the main field wiring interface for the contractor.
See Carrier Specification Z-415 for specific starter requirements. All starters must meet these specifications in order to
properly start and satisfy mechanical safety requirements.
Starters may be supplied as separate, free-standing units or may
be mounted directly on the chiller (unit mounted) for low-voltage units only.
Multiple separate circuit breakers are inside the starter. Circuit breaker CB1 is the compressor motor circuit breaker. The
disconnect switch on the starter front cover is connected to this
breaker. Circuit breaker CB1 supplies power to the compressor
motor.
Pumpout compressor voltage must be the same as the compressor motor voltage.
All starters must include a Carrier control module called the
Integrated Starter Module (ISM), excluding the Benshaw solidstate starters. This module controls and monitors all aspects of
the starter. See the Controls section on page 14 for additional
ISM information. All starter replacement parts are supplied by
the starter manufacturer excluding the ISM (contact Carrier’s
Replacement Component Division [RCD]).
The main circuit breaker (CB1) on the front of the starter
disconnects the main motor current only. Power is still
energized for the other circuits. Two more circuit breakers
inside the starter must be turned off to disconnect power to
the PIC II controls, and TC frame 1 and 2 chillers oil
heater.
12
Unit-Mounted Solid-State Starter (Optional) —
The 23XL chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 8 and 9). This starter’s primary function is
to provide on-off control of the compressor motor. This type of
starter reduces the peak starting torque, reduces the motor
inrush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” The solid-state
starter is available as a 23XL option (factory supplied and
installed). The solid-state starters manufacturer name is located
inside the starter access door.
A solid-state, reduced-voltage starter operates by reducing
the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the
voltage and the current are reduced at start-up, the starting
torque is reduced as well. The object is to reduce the starting
voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage is reduced by silicon controlled rectifiers (SCRs). The voltage and current are
then ramped up in a desired period of time. Once full voltage is
reached, a bypass contactor is energized to bypass the SCRs.
6
1
2
3
5
4
When voltage is supplied to the solid-state circuitry, the
heat sinks in the starter as well as the wires leading to the
motor and the motor terminal are at line voltage. Do not
touch the heat sinks, power wiring, or motor terminals
while voltage is present or serious injury will result.
LEGEND
1 — REDISTART™Micro Input/Output Card
2 — Circuit Breaker 2 (CB2):
Machine Control and Heater Power
3 — Circuit Breaker 3 (CB3): Pumpout Unit
4 — REDISTART Micro Central Processing Unit Card (CPU)
5 — Restart Micro Power Card (hidden, not depicted)
6 — Restart Micro Bypass Card (hidden, not depicted)
There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter
checkout. The display indicates:
• voltage to the SCRs
• power indication
• proper phasing for rotation
• start circuit energized
• run state
• software configuration
The starter is further explained in the Check Starter and
Troubleshooting Guide sections, pages 59 and 76.
Fig. 8 — Solid-State Starter Box,
Internal View
Unit-Mounted Wye-Delta Starter (Optional) —
The 23XL chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is intended for use with lowvoltage motors (under 600 v). It reduces the starting current
inrush by connecting each phase of the motor windings into a
wye configuration. This occurs during the starting period when
the motor is accelerating up to speed. Once the motor is up to
speed, the starter automatically connects the phase windings
into a delta configuration. Starter control, monitoring, and
motor protection is provided by Carrier’s Integrated Starter
Module (ISM).
Fig. 9 — Typical Starter External View
(Solid-State Starter Shown)
13
CONTROLS
PIC II System Components — The chiller control
system is called PIC II (Product Integrated Control II). See Table 2. The PIC II controls the operation of the chiller by monitoring all operating conditions. The PIC II can diagnose a problem and let the operator know what the problem is and what to
check. It promptly positions the slide valve to maintain leaving
chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on
when required. It continually checks all safeties to prevent any
unsafe operating condition. It also regulates the oil heater while
the compressor is off and regulates the hot gas bypass valve, if
installed. The PIC II controls provide critical protection for the
compressor motor and controls the motor starter.
The PIC II can interface with the Carrier Comfort Network
(CCN) if desired. It can communicate with other PIC I or
PIC II equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 2 and Fig. 11-16):
• control panel
all extra low-voltage wiring (24 v or less)
• power panel
230 or 115 v control voltage (per job requirement)
• starter cabinet
chiller power wiring (per job requirement)
Definitions
ANALOG SIGNAL — An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position representation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
General Controls Overview — The 23XL hermetic
screw liquid chiller contains a microprocessor-based control
center that monitors and controls all operations of the chiller.
The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-ofthe-art chiller protection. The system controls cooling capacity
within the set point plus the deadband by sensing the leaving
chilled water or brine temperature and regulating the slide
valve via a mechanically linked, hydraulically actuated piston.
Movement of the slide valve alters the point during rotor travel
at which compression begins and reduces the effective length
of the compression cavities. This permits internal gas recirculation and reduces suction volume. Thus, smooth, stepless capacity regulation is provided in the load direction. Moving of the
slide valve increases capacity. Moving of the slide valve in the
unload direction decreases capacity. See Fig. 10. Chiller protection is provided by the processor, which monitors the digital
and analog inputs and executes capacity overrides or safety
shutdowns, if required.
Table 2 — Major PIC II Components and
Panel Locations*
PIC II COMPONENT
Chiller Visual Controller (CVC) and
Display
Integrated Starter Module (ISM)
Chiller Control Module (CCM)
Oil Heater Contactor (1C)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1, T2)
Temperature Sensors
Pressure Transducers
PANEL LOCATION
Control Panel
Starter Cabinet
Control Panel
Power Panel
Power Panel
Power Panel
See Fig. 11 and 12.
See Fig. 11 and 12.
*See Fig. 8 and Fig. 11-16.
CHILLER VISUAL CONTROLLER (CVC) — The CVC is
the “brain” of the PIC II. This module contains all the primary
software needed to control the chiller. The CVC is mounted to
the control panel (Fig. 15) and is the input center for all local
chiller set points, schedules, configurable functions, and options. The CVC has a stop button, an alarm light, four buttons
for logic inputs, and a backlight display. The backlight will automatically turn off after 15 minutes of non-use. The functions
of the four buttons or “softkeys” are menu driven and are
shown on the display directly above the softkeys. The CVC is
mounted in the Control Panel.
The angle of the control panel can be adjusted for optimum
viewing. Remove the 2 bolts connecting the control panel to
the brackets attached to the cooler. Place them in one of the
holes to pivot the control panel forward to backward to change
the viewing angle. See Fig. 15. To change the contrast of the
display, access the adjustment on the back of the CVC. See
Fig. 15.
Fig. 10 — Slide-Valve Capacity Control
14
*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components).
Fig. 11 — 23XL Control and Sensor Locations (TC Frame 1 and 2 Chillers)
15
*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components).
Fig. 12 — 23XL Control and Sensor Locations (TD Frame 4 Chillers)
16
CONTROL TRANSFORMERS (T1, T2) — These
transformers convert incoming control voltage to 24 vac power for
the 3 power panel contactor relays, CCM, and CVC.
INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the CVC for starter functions such as starting and
stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, 4 to 20 mA Head Pressure Reference output, and the shunt trip. The ISM monitors starter inputs
such as line voltage, motor current, ground fault, remote start
contact, spare safety, condenser high pressure, starter 1M, and
run contacts. The ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the
CVC are lost.
CHILLER CONTROL MODULE (CCM) — This module is
located in the control panel. The CCM provides the input and
outputs necessary to control the chiller. This module monitors
refrigerant pressure, entering and leaving water temperatures
and pressures, and outputs control for the slide valve oil heaters, and oil pump. The CCM is the connection point for optional demand limit, chilled water reset, 4 to 20 mA kW output, remote temperature reset, and refrigerant leak sensor.
OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 16) and operates the heater at either 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional) — This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC II energizes
the relay during low load, high lift conditions.
Fig. 13 — Control Sensors (Temperature)
Fig. 14 — Control Sensors
(Pressure Transducers, Typical)
17
Fig. 15 — Control Panel
Fig. 16 — Power Panel
18
CVC Operation and Menus (Fig. 17-23)
PRIMARY STATUS
MESSAGE
GENERAL
• The CVC display automatically reverts to the default
screen after 15 minutes if no softkey activity takes place
(Fig. 17).
• If a screen other than the default screen is displayed on
the CVC, the name of that screen is in the upper right
corner (Fig. 18).
• The CVC may be set to display either English or SI
units. Use the CVC configuration screen (accessed from
the Service menu) to change the units. See the Service
Operation section, page 46.
• Local Operation — The PIC II can be placed in local
operating mode by pressing the LOCAL softkey. The
PIC II then accepts commands from the CVC only and
uses the Local Time Schedule to determine chiller start
and stop times.
• CCN Operation — The PIC II can be placed in the CCN
operating mode by pressing the CCN softkey. The PIC
II then accepts modifications from any CCN interface or
module (with the proper authority), as well as from the
CVC. The PIC II uses the CCN time schedule to determine start and stop times.
SECONDARY
STATUS
MESSAGE
•
CHW IN
CDW IN
44.1
CDW OUT
85.0
OIL PRESS
21.8
CCN
TIME
01-01-95 11:48
28.8 HOURS
CHW OUT
55.1
CONTINUOUSLY
• BLINKS
ON FOR AN ALARM
BLINKS
TO
• CONFIRMONCE
A STOP
EVAP REF
40.7
COND REF
95.0
98.1
OIL TEMP
AMPS %
132.9
LOCAL
RESET
93
MENU
STOP BUTTON
FOR ONE
• HOLD
SECOND TO STOP
SOFT KEYS
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
MENU
LINE
Fig. 17 — CVC Default Screen
23XL_II
SERVICE
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
Fig. 18 — CVC Service Screen
•
The SERVICE menu can be used to view or modify
information on the Alarm History, Control Test, Control
Algorithm Status, Equipment Configuration, ISM
Starter Configuration data, Equipment Service, Time
and Date, Attach to Network Device, Log Out of Network Device, and CVC Configuration screens.
For more information on the menu structures, refer to
Fig. 20.
Press the softkey that corresponds to the menu structure to
be viewed: STATUS , SCHEDULE , SETPOINT , or
SERVICE . To view or change parameters within any of
these menu structures, use the NEXT and PREVIOUS softkeys to scroll to the desired item or table. Use the SELECT
softkey to select that item. The softkey choices that then appear
depend on the selected table or menu. The softkey choices and
their functions are described below.
CVC MENU ITEMS — To perform any of the operations
described below, the PIC II must be powered up and have successfully completed its self test. The self test takes place automatically, after power-up.
Press the MENU softkey to view the list of menu structures:
STATUS ,
SCHEDULE ,
SETPOINT , and
SERVICE .
•
DATE
RUNNING TEMP CONTROL
LEAVING CHILLED WATER
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
ALARMS AND ALERTS — An alarm shuts down the compressor. An alert does not shut down the compressor, but it notifies the operator that an unusual condition has occurred. An
alarm (*) or alert (!) is indicated on the STATUS screens on the
far right field of the CVC display screen.
Alarms are indicated when the control center alarm light (!)
flashes. The primary alarm message is displayed on the default
screen. An additional, secondary message and troubleshooting
information are sent to the ALARM HISTORY table.
When an alarm is detected, the CVC default screen will
freeze (stop updating) at the time of alarm. The freeze enables
the operator to view the chiller conditions at the time of alarm.
The STATUS tables will show the updated information. Once
all alarms have been cleared (by pressing the RESET softkey), the default CVC screen will return to normal operation.
•
COMPRESSOR
ON TIME
The STATUS menu allows viewing and limited calibration or modification of control points and sensors, relays
and contacts, and the options board.
The SCHEDULE menu allows viewing and modification of the local and CCN time schedules and Ice Build
time schedules.
The SETPOINT menu allows set point adjustments,
such as the entering chilled water and leaving chilled
water set points.
BASIC CVC OPERATIONS (Using the Softkeys) — To
perform any of the operations described below, the PIC II must
be powered up and have successfully completed its self test.
19
•
•
Press ENTER to leave the selected decision or field and
save changes.
•
Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current screen.
•
•
2. Press NEXT or PREVIOUS to highlight the desired
status table. The list of tables is:
Press QUIT to leave the selected decision or field without saving any changes.
• MAINSTAT — Overall chiller status
• STARTUP — Status required to perform start-up of
chiller
• COMPRESS — Status of sensors related to the
compressor
• HEAT_EX — Status of sensors related to the heat
exchangers
• POWER — Status of motor input power
• ISM_STAT — Status of motor starter
• CVC_PSWD — Service menu password forcing
access screen
3. Press SELECT to view the desired point status table.
Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
4. On the point status table, press NEXT or
PREVIOUS until the desired point is displayed on the
screen.
Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted point value.
•
Press EXIT to return to the previous screen level.
•
Press INCREASE or DECREASE to change the highlighted point value.
23XL_II MAINSTAT
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
Chiller Start/Stop
Remote Start Contact
Temperature Reset
Control Point
Chilled Water Temp
Active Demand Limit
Average Line Current
POINT STATUS
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
Fig. 19 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT
PREVIOUS to highlight the desired value.
TO VIEW STATUS (Fig. 19) — The status table shows the
actual value of overall chiller status such as CONTROL
MODE, RUN STATUS, AUTO CHILLED WATER, RESET,
and REMOTE RESET SENSOR.
1. On the menu screen, press STATUS to view the list
of point status tables.
20
or
DEFAULT SCREEN
LOCAL
CCN
RESET
MENU
(SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
Access Main Menu
STATUS
SCHEDULE
SETPOINT
1 1 1 1 (ENTER A 4-DIGIT PASSWORD)
List the
Status Tables
List the Service Tables
Display The Setpoint Table
• MAINSTAT
• STARTUP
• COMPRESS
• HEAT_EX
• POWER
• ISM_STAT
• CVC_PSWD
Select a Status Table
PREVIOUS
NEXT
Select a Modification Point
PREVIOUS
NEXT
Modify a Discrete Point
START
STOP
ON
OFF
Modify an Analog Point
INCREASE DECREASE
Modify Control Options
DISABLE
ENABLE
SERVICE
List the Schedules
EXIT
• Base Demand Limit
• LCW Setpoint
• ECW Setpoint
• Ice Build Setpoint
• Tower Fan High Setpoint
Select the Setpoint
SELECT
PREVIOUS
NEXT
SELECT
EXIT
Modify the Setpoint
INCREASE DECREASE
RELEASE
ENTER
RELEASE
ENTER
QUIT
ENTER
SELECT
QUIT
EXIT
ENTER
• OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
• OCCPC03S – CCN TIME SCHEDULE
Select a Schedule
SELECT
PREVIOUS
EXIT
NEXT
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
SELECT
PREVIOUS
NEXT
EXIT
Modify a Schedule Time
INCREASE DECREASE
ENTER
EXIT
(ANALOG VALUES)
Add/Eliminate a Day
ENABLE
DISABLE
ENTER
EXIT
(DISCRETE VALUES)
NEXT
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
SELECT
PREVIOUS
EXIT
SEE FIGURE 21
Fig. 20 — 23XL CVC Menu Structure
21
SERVICE TABLE
NEXT
PREVIOUS
SELECT
EXIT
ALARM HISTORY
Display Alarm History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL TEST
List the Control Tests
• CCM Thermistors
• CCM Pressure Transducers
• Pumps
• Discrete Outputs
• Slide Valve Control
• Head Pressure Output
• VFD Speed Control
• Pumpdown/Lockout
• Terminate Lockout
• Refrigerant Type
CONTROL ALGORITHM STATUS
List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• OVERRIDE (Override Status)
• LL_MAINT (Lead Lag Status)
• ISM_HIST (ISM Alarm History)
• LOADSHED
• WSMCHLRE (Water System Manager)
• OCCDEFCM (Time Schedule Status)
Select a Table
SELECT
PREVIOUS
NEXT
Select a Test
NEXT
PREVIOUS
SELECT
EXIT
EXIT
OCCDEFM (Time Schedule Status)
Data Select Table
PREVIOUS
NEXT
SELECT
• CAPACITY (Capacity Control Algorithm)
• OVERRIDE (Override Status)
• LL_MAINT (LEADLAG Status)
• WSMDEFM2 (Water System Manager Control Status)
EXIT
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
EQUIPMENT CONFIGURATION
Maintenance Table Data
List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
PREVIOUS
NEXT
SELECT
Select a Parameter
PREVIOUS
NEXT
EXIT
SELECT
Modify a Parameter
INCREASE DECREASE
ENABLE
DISABLE
QUIT
ENTER
(ANALOG VALUES)
QUIT
ENTER
(DISCRETE VALUES)
CONTINUED
ON NEXT PAGE
Fig. 21 — 23XL Service Menu Structure
22
EXIT
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
Service Tables:
• OPTIONS
• SETUP1
• SETUP2
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
PREVIOUS
NEXT
Service Tables:
• ISM (STARTER) CONFIG PASSWORD
• ISM_CONF
SELECT
EXIT
Select a Service Table Parameter
SELECT
PREVIOUS
NEXT
EXIT
Modify a Service Table Parameter
INCREASE DECREASE
QUIT
ENABLE
DISABLE
QUIT
ENTER
(ANALOG VALUES)
ENTER
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
• To Modify — Current Time
— Current Date
INCREASE DECREASE
ENTER
ATTACH TO NETWORK DEVICE
List Network Devices
• Device 6
• Local
• Device 1 • Device 7
• Device 2 • Device 8
• Device 3 • Device 9
• Device 4 • Attach To Any Device
• Device 5
Select a Device
PREVIOUS
NEXT
SELECT
YES
NO
ENTER
— Day of Week
— Holiday Today
(ANALOG VALUES)
EXIT
EXIT
(DISCRETE VALUES)
ATTACH
Modify Device Address
INCREASE DECREASE
ENTER
EXIT
• Use to attach CVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
LOCAL
CCN
RESET
MENU
CVC CONFIGURATION
CVC Configuration Table
INCREASE DECREASE
CCN
CVC
IMP
ISM
PIC II
—
—
—
—
—
LEGEND
Carrier Comfort Network
Chiller Visual Controller
Imperial
Integrated Starter Module
Product Integrated Control II
ENTER
EXIT
• To View — CVC Software Version
• To Modify — CVC CCN Address
(last 2 digits of part number
— English (US IMP) or S.I. Metric Units
indicate software version)
— Password
Fig. 21 — 23XL Service Menu Structure (cont)
23
TIME SCHEDULE OPERATION (Fig. 22)
1. On the Menu screen, press SCHEDULE .
2. Press SELECT to select the highlighted value. Then:
For Discrete Points — Press YES
select the desired state.
YES
or
NO
to
2. Press NEXT or PREVIOUS to highlight the desired schedule.
NO
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03S — CCN Time Schedule
For Analog Points — Press INCREASE
DECREASE to select the desired value.
or
3. Press SELECT to view the desired time schedule.
3. Press ENTER to register the new value.
4. Press NEXT or PREVIOUS to highlight the desired period or override to change.
NOTE: When overriding or changing metric values, it is necessary to hold down the softkey for a few seconds in order to
see a value change, especially on kilopascal values.
To Remove an Override
1. On the point status table press NEXT
or
PREVIOUS to highlight the desired value.
5. Press SELECT to access the highlighted period or
override.
2. Press SELECT to access the highlighted value.
6. a Press INCREASE or DECREASE to change the
time values. Override values are in one-hour
increments, up to 4 hours.
3. Press RELEASE to remove the override and return
the point to the PIC II’s automatic control.
23XL
Override Indication — An override value is indicated by
“SUPVSR,” “SERVC,” or “BEST” flashing next to the point
value on the STATUS table.
Fig. 22 — Example of Time Schedule
Operation Screen
24
2. There are 5 set points on this screen: BASE DEMAND
LIMIT, LCW SETPOINT (leaving chilled water set
point), ECW SETPOINT (entering chilled water set
point), ICE BUILD SETPOINT, and TOWER FAN
HIGH SETPOINT. Only one of the chilled water set
points can be active at one time. The set point that is
active is determined from the SERVICE menu. See the
Service Operation section, page 46. The ice build (ICE
BUILD) function is also activated and configured from
the SERVICE menu.
3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
b. Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the
period.
7. Press ENTER to register the values and to move horizontally (left to right) within a period.
8. Press EXIT to leave the period or override.
4. Press SELECT to modify the highlighted set point.
9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time
schedule screen and save the changes.
5. Press INCREASE or DECREASE to change the selected set point value.
6. Press ENTER to save the changes and return to the
previous screen.
10. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 46. The
month, day, and duration for the holiday must be
assigned. The Broadcast function in the BRODEF
table also must be enabled for holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 23)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
23XL_II
SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation
section, page 46. For examples of CVC display screens, see
Table 3.
SETPOINT SELECT
100%
50.0 F
60.0 F
40.0 F
85.0 F
Fig. 23 — Example of Set Point Screen
25
Table 3 — CVC Display Data
6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized
names, those preceded by a dagger can also be changed (that
is, written to) by the CCN, BS, and the CVC. Capitalized Reference Point Names preceded by two asterisks can be changed
only from the CVC. Reference Point Names in lower case type
can be viewed by CCN or BS only by viewing the whole table.
7. Alarms and Alerts: An asterisk in the far right field of a CVC status screen indicates that the chiller is in an alarm state; an exclamation point in the far right field of the CVC screen indicates an
alert state. The asterisk (or exclamation point) indicates that the
value on that line has exceeded (or is approaching) a limit. For
more information on alarms and alerts, see the Alarms and
Alerts section, page 19.
LEGEND
— Motor Overload
12T
— Control Relay
1CR
— Carrier Comfort Network
CCN
— Chilled Water
CHW
— Control Relay
CR
— Current Transformer
CT
— Chiller Visual Controller
CVC
— Entering Chilled Water
ECW
HGBP — Hot Gas Bypass
— Integrated Starter Module
ISM
— Leaving Chilled Water
LCW
— Locked Rotor Amps
LRA
— Milliamps
mA
— Pressure
P
— Solid State
SS
— Temperature
T
— Slide Valve
SV
— Variable Frequency Drive
VFD
— Water System Manager
WSM
IMPORTANT: The following notes apply to all Table 3
examples.
1. Only 12 lines of information appear on the CVC screen at any
one time. Press the NEXT or PREVIOUS softkey to highlight
a point or to view items below or above the current screen.
Double-click the NEXT softkey to page forward; double-click
the PREVIOUS softkey to page back.
2. To access the information shown in Examples 9 through 21,
enter your 4-digit password after pressing the SERVICE softkey. If no softkeys are pressed for 15 minutes, the CVC automatically logs off (to prevent unrestricted access to PIC II controls)
and reverts to the default screen. If this happens, you must reenter your password to access the tables shown in Examples 9
through 21.
3. Terms in the Description column of these tables are listed as
they appear on the CVC screen.
4. The CVC may be configured in English or Metric (SI) units using
the CVC CONFIGURATION screen. See the Service Operation
section, page 46, for instructions on making this change.
5. The items in the Reference Point Name column do not appear on
the CVC screen. They are data or variable names used in CCN
or Building Supervisor (BS) software. They are listed in these
tables as a convenience to the operator if it is necessary to cross
reference CCN/BS documentation or use CCN/BS programs. For
more information, see the 23XL CCN literature.
EXAMPLE 1 — CVC DEFAULT SCREEN
The following data is displayed in the CVC Default screen.
DESCRIPTION
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime
Entering Chilled Water
Leaving Chilled Water
Evaporator Temperature
Entering Condenser Water
Leaving Condenser Water
Condenser Temperature
Oil Pressure
Oil Sump Temp
Average Line Current
RANGE
UNITS
0-500000.0
–40-245
–40-245
–40-245
–40-245
–40-245
–40-245
0-420
40-245
0-999
0-1
0-1
0-1
HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%
REFERENCE POINT NAME
(ALARM HISTORY)
C_HRS
ECW
LCW
ERT
ECDW
LCD
CRT
OILPD
OILT
AMPS_%
CCN
LOCAL
RESET
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC only.
26
DISPLAY
CHW IN
CHW OUT
EVAP REF
CDW IN
WCDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %
Table 3 — CVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
DESCRIPTION
Control Mode
Run Status
Start Inhibit Timer
Occupied ?
System Alert/Alarm
*Chiller Start/Stop
*Remote Start Contact
Temperature Reset
*Control Point
Chilled Water Temp
*Active Demand Limit
Average Line Current
Motor Percent Kilowatts
Auto Demand Limit Input
Auto Chilled Water Reset
Remote Reset Sensor
Total Compressor Starts
Starts in 12 Hours
Compressor Ontime
*Service Ontime
Ice Build Contact
Refrigerant Leak Sensor
STATUS
NOTE 1
NOTE 2
0-15
0/1
0-2
0/1
0/1
–30-30
10-120
–40-245
40-100
0-999
0-999
4-20
4-20
–40-245
0-99999
0-8
0-500000.0
0-32767
0-1
0-20
UNITS
NOTE 1
NOTE 2
min
NO/YES
NOTE 3
STOP/START
OFF/ON
DEG F
DEG F
DEG F
%
%
%
mA
mA
DEG F
HOURS
HOURS
OPEN/CLOSE
mA
POINT
CMODE
RUNSTAT
T_START
OCC
SYS_ALM
CHIL_S_S
REMCON
T_RESET
LCW_STPT
CHW_TMP
DEM_LIM
AMPS_%
KW_P
AUTODEM
AUTORES
R_RESET
C_STARTS
STARTS
C_HRS
S_HRS
ICE_CON
REF_LEAK
NOTES:
1. Reset, Off, Local, CCN
2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
3. Normal, Alert, Alarm
4. All variables with capital letter point names are available for CCN read operation.
Those shown with (*) support write operations for all CCN devices.
EXAMPLE 3 — STARTUP DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .
DESCRIPTION
Slide Valve Unload Timer
**Chilled Water Pump
Chilled Water Flow
**Condenser Water Pump
Condenser Water Flow
Oil Pump Relay
**Oil Delta P
Compressor Start Relay
Compressor Start Contact
Starter Trans Relay
Compressor Run Contact
**Tower Fan Relay Low
**Tower Fan Relay High
Starter Fault
Spare Safety Input
Shunt Trip Relay
Oil Level Sensor
ISM Fault Status
STATUS
0-2
0-1
0-1
0-1
0-1
0-1
–67-2009
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-255
UNITS
MIN
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
^PSI
OFF/ON
OPEN/CLOSED
OFF/ON
OPEN/CLOSED
OFF/ON
OFF/ON
ALARM/NORMAL
ALARM/NORMAL
OFF/ON
OPEN/CLOSED
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
Those shown with (**) shall support write operations for the CVC only.
27
POINT
SV_TIMER
CHWP
CHW_FLOW
CDP
CDW_FLOW
OILR
OILPD
CMPR
1CR_AUX
CMPTRANS
RUN_AUX
TFR_LOW
TFR_HIGH
STR_FLT
SAFETY
TRIPR
OIL_LEV
STRSTAT
Table 3 — CVC Display Data (cont)
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .
DESCRIPTION
Slide Valve Load
Slide Valve Unload
Manual SV Load/Unload
Slide Valve Duty Cycle
**Oil Delta P
Oil Pressure Required
Oil Filter Data
Oil Sump Temperature
Oil Heater Relay
Comp Motor Winding Temp
Rotor Inlet Temperature
Discharge Temperature
Discharge Superheat
Variable Index Relay
Target VFD Speed
Actual VFD Speed
Stall Protection Counts
Spare Temperature 1
Spare Temperature 2
STATUS
0-5
0-5
–10-10
–100-100
–6.7-200
0-20
0-120
–40-245
0/1
–40-245
–40-245
–40-245
–40-245
0/1
1-100
0-110
0-5
–40-245
–40-245
UNITS
SEC
SEC
SEC
%
PSI
PSI
PSI
DEG F
OFF/ON
DEG F
DEG F
DEG F
^F
OFF/ON
%
%
DEG F
DEG F
POINT
SV_LD
SV_UNLD
SV_MAN
SV_DUTY
OILPD
OILP__REQ
OILF_PD
OILT
OILH
MTRW
ROTOR _ T
CMPD
SUPRHEAT
VAR_INDX
VFD_OUT
VFD_ACT
spc
SPARE1
SPARE2
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
those with (**) shall support write operations for CVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .
DESCRIPTION
**Chilled Water Delta P
Entering Chilled Water
Leaving Chilled Water
Chilled Water Delta T
Chil Water Pulldown/Min
Evaporator Refrig Temp
**Evaporator Pressure
Evaporator Approach
**Condenser Water Delta P
Entering Condenser Water
Leaving Condenser Water
Condenser Refrig Temp
**Condenser Pressure
Condenser Approach
Hot Gas Bypass Relay
Stall/HGBP Active?
Active Delta P
Active Delta T
Stall/HGBP Delta T
Head Pressure Reference
STATUS
–6.7-420
–40-245
–40-245
–40-245
–20-20
–40-245
–6.7-420
0-99
–6.7-420
–40-245
–40-245
–40-245
–6.7-420
0-99
0/1
0/1
0-200
0-200
0-200
0-100
UNITS
PSI
DEG F
DEG G
^F
^F
DEG F
PSI
^F
PSI
DEG F
DEG F
DEG F
PSI
^F
OFF/ON
NO/YES
PSI
^F
^F
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
those with (**) shall support write operations for CVC only.
28
POINT
CHW_PD
ECW
LCW
CHW_DET
CHW_PULL
ERT
ERP
EVAP_APP
COND_PD
ECDW
LCDW
CRT
CRP
COND_APP
HGBR
SHG_ACT
dp_a
dt_c
dt_c
hpr
Table 3 — CVC Display Data (cont)
EXAMPLE 6 — POWER DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .
DESCRIPTION
Average Line Current
Actual Line Current
Average Line Voltage
Actual Line Voltage
Power Factor
Motor Kilowatts
**Motor Kilowatt-Hours
Demand Kilowatts
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 4
Frequency
12T Sum Heat-Phase 1
12T Sum Heat-Phase 2
12T Sum Heat-Phase 3
STATUS
0-999
0-99999
0-999
0-99999
0.0-1.0
0-99999
0-999999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-99
0-200
0-200
0-200
UNITS
%
AMPS
%
VOLTS
KW
KWH
KW
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
HZ
%
%
%
POINT
%_AMPS
AMP_A
VOLT_P
VOLT_A
PF
KW_A
KWH
DEM_KW
AMPS_1
AMPS_2
AMPS_3
VOLTS_1
VOLTS_2
VOLTS_3
GF_1
GF_2
GF_3
FREQ
HEAT1SUM
HEAT2SUM
HEAT3SUM
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
Those with (**) shall support write operations for CVC only.
EXAMPLE 7 — ISM_STAT SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ISM_STAT .
4. Press SELECT .
DESCRIPTION
ISM Fault Status
Single Cycle Dropout
Phase Loss
Overvoltage
Undervoltage
Current Imbalance
Voltage Imbalance
Overload Trip
Locked Rotor Trip
Starter LRA Trip
Ground Fault
Phase Reversal
Frequency Out of Range
ISM Power on Reset
Phase 1 Fault
Phase 2 Fault
Phase 3 Fault
ICR Start Complete
1M Start/Run Fault
2M Start/Run Fault
Pressure Trip Contact
Starter Fault
Motor Amps Not Sensed
Starter Acceleration Fault
High Motor Amps
1CR Stop Complete
1M/2M Stop Fault
Motor Amps When Stopped
Hardware Failure
STATUS
0-223
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
UNITS
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
29
POINT
ISMFLT
CYCLE_1
PH_LOSS
OV_VOLT
UN_VOLT
AMP_UNB
VOLT_UNB
OVERLOAD
LRATRIP
SLRATRIP
GRND_FLT
PH_REV
FREQFLT
ISM_POR
PHASE_1
PHASE_2
PHASE_3
START_OK
1M_FLT
2M_FLT
PRS_RIP
STRT_FLT
NO_AMPS
ACCELFLT
HIGHAMPS
STOP_OK
1M2MSTOP
AMPSTOP
HARDWARE
Table 3 — CVC Display Data (cont)
EXAMPLE 8 — SETPOINT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SETPOINT (Base Demand Limit will be highlighted) .
3. Press SELECT .
DESCRIPTION
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
STATUS
40-100
UNITS
%
POINT
DLM
DEFAULT
100
10-120
15-120
15-60
55-105
DEG F
DEG F
DEG F
DEG F
lcw_sp
ecw_sp
ice_sp
tf2_sp
50.0
60.0
40.0
75
NOTE: No variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 9 — CAPACITY DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight CAPACITY .
DESCRIPTION
Entering Chilled Water
Leaving Chilled Water
Capacity Control
Control Point
Control Point Error
ECW Delta T
ECW Reset
LCW Reset
Total Error + Resets
Slide Valve Delta
Slide Valve Load
Slide Valve Unload
Variable Index Relay
Target VFD Speed
Actual VFD Speed
VFD Gain
Demand Limit Inhibit
Amps/kW Ramp
STATUS
–40-245
–40-245
UNITS
DEG F
DEG F
POINT
ECW
LCW
7-120
–99-99
–99-99
–99-99
–99-99
–99-99
–2-2
0-5
0-5
0-1
0-100
0-100
0.1-1.5
0-1
0-100
DEG F
^F
^F
^F
^F
^F
%
SEC
SEC
OFF/ON
%
%
ctrlpt
cperr
ecwdt
ecwres
lcwres
error
svd
SV_LD
SV_UNLD
VARINDEX
VFD_IN
VFD_ACT
vfd_gain
DEM_INH
DEMLIM
%
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
forcing shall not be supported on maintenance screens.
30
Table 3 — CVC Display Data (cont)
EXAMPLE 10 — OVERRIDE DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .
DESCRIPTION
Comp Motor Winding Temp
Comp Motor Temp Override
Condenser Pressure
Cond Press Override
Evaporator Refrig Temp
Evap Ref Override Temp
Comp Discharge Temp
Comp Discharge Alert
Oil Filter Delta P
Discharge Superheat
Rotor Inlet Temperature
Condenser Refrig Temp
STATUS
–40-245
150-200
0-420
150-260
–40-245
2-245
–40-245
125-200
0-245
–20-999
–40-245
–40-245
UNITS
DEG F
DEG F
PSI
PSI
DEG F
DEG F
DEG F
DEG F
PSI
^F
DEG F
DEG F
POINT
MTRW
MT_OVER
CRP
CP_OVER
ERT
RT_OVER
CMPD
CD_ALERT
OILF_PD
SUPRHEAT
ROTOR_T
CRT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on
maintenance screens.
EXAMPLE 11 — LL_MAINT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight LL_MAINT. .
DESCRIPTION
Lead Lag Control
LEADLAG: Configuration
Current Mode
Load Balance Option
LAG Start Time
LAG Stop Time
Prestart Fault Time
Pulldown: Delta T/Min
Satisfied ?
LEAD CHILLER in Control
LAG CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
STANDBY CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
Spare Temperature 1
Spare Temperature 2
STATUS
NOTE 1
NOTE 2
NOTE 3
0/1
2-60
2-60
2-30
x.xx
0/1
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
–40-245
–40-245
UNITS
DSABLE/ENABLE
MIN
MIN
MIN
^F
NO/YES
NO/YES
NO/YES
NO/YES
DEG F
DEG F
POINT
leadlag
leadlag
llmode
loadbal
lagstart
lagstop
preflt
pull_dt
pull_sat
leadctrl
lagmode
lagstat
lag_s_s
lag_rec
stdmode
stdstat
std_s_s
std_rec
SPARE_T1
SPARE_T2
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation;
forcing shall not be supported on maintenance screens.
31
Table 3 — CVC Display Data (cont)
EXAMPLE 12 — ISM_HIST DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight ISM_HIST .
DESCRIPTION
ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 4
12T Sum Heat-Phase 1
12T Sum Heat-Phase 2
12T Sum Heat-Phase 3
Line Frequency
ISM FAULT STATUS
STATUS
UNITS
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-200
0-200
0-200
0-99
0-9999
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
%
%
%
HZ
POINT
AMPS_1F
AMPS_2F
AMPS_3F
VOLTS_1F
VOLTS_2F
VOLTS_3F
GF_1F
GF_2F
GF_3F
HEAT1SUMF
HEAT2SUMF
HEAT3SUMF
FREQ_F
ISM_STAT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
forcing shall not be supported on maintenance screens.
EXAMPLE 13 — WSMCHLRE DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight WSMCHLRE .
DESCRIPTION
WSM Active?
Chilled Water Temp
Equipment Status
Commanded State
CHW setpt Reset Value
Current CHW Set Point
STATUS
0/1
0.0-99.9
0/1
XXXXXXXX
0.0-25.0
0.0-99.9
UNITS
NO/YES
DEG F
OFF/ON
TEXT
DEG F
DEG F
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
forcing shall not be supported on maintenance screens.
32
POINT
WSMSTAT
CHWTEMP
CHLRST
CHLRENA
CHWRVAL
CHWSTPT
Table 3 — CVC Display Data (cont)
EXAMPLE 14 — NET_OPT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .
DESCRIPTION
Loadshed Function
Group Number 1-16
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing
STATUS
UNITS
POINT
DEFAULT
0-06
30-480
%
MIN
ldsgrp
ldsdelta
maxldstm
0
20
60
3-99
0-1
DSABLE/ENABLE
occpcxxe
occbrcst
3
DSABLE
0-1440
00000000-11111111
MIN
30
10000000
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 15 — ISM_CONF DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight ISM (STARTER) CONFIG DATA.
4. Press SELECT .
5. Scroll down to highlight ISM_CONF .
DESCRIPTION
Starter Type
(0 = Full, 1 = Red, 2 = SS/VFD)
Motor Rated Line Voltage
Volt Transformer Ratio:1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage % Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio:
Current % Imbalance
Current Imbalance Time
3 Grnd Fault CT’s? (1 = No)
Ground Fault CT Ratio:1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency = 60 Hz? (No = 50)
Line Frequency Faulting
STATUS
0-2
200-13200
1-33
105-115
85-95
1-10
1-10
1-10
10-5000
100-60000
1-10
100-60000
13-1000
5-40
1-10
0-1
150
1-25
1-20
1-10
0/1
0/1
0/1
UNITS
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
NOTE: No variables are available for CCN read or write operation.
33
POINT
starter
DEFAULT
1
v_fs
vt_rat
overvolt
undvolt
uvuntime
v_unbal
v_time
a_fs
motor_r
lrdelay
star_lr
ct_turns
c_unbal
c_time
gf_phase
gf_ctr
gf_amps
gf_delay
gf_pers
cycdrop
freq
freq_en
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
Table 3 — CVC Display Data (cont)
EXAMPLE 16 — OPTIONS DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight OPTIONS .
DESCRIPTION
Auto Restart Option
Remote Contacts Open
Soft Stop Amps Threshold
Stall/Hot Gas Bypass
Stall Limit/HGBP Option
Select: Stall=0, HGBP=1
Min. Load Point (T1/P1)
Stall/HGBP Delta T1
Stall/HGBP Delta P1
Full Load Point (T2/P2)
Stall/HGBP Delta T2
Stall/HGBP Delta P2
Stall/HGBP Deadband
Stall Protection
Stall Delta % Amps
Stall Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
Refrigerant Leak Option
Refrigerant Leak Alarm
Head Pressure Reference
Delta P @ 0% (4mA)
Delta P @ 100% (20mA)
Minimum Output
STATUS
0/1
0/1
40-100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1
POINT
astart
r_contact
softstop
DEFAULT
DSABLE
DSABLE
100
stall_hgbp
0
0.5-20
30-170
^F
PSI
hgb_dt1
hgb_dp1
1.5
150
0.5-20
30-250
0.5-3
^F
PSI
^F
hbg-dt2
hgb_dp2
hbg_db
4
200
1
5-20
7-10
%
MIN
stall_a
stall_t
10
8
0-1
0-2
DSABLE/ENABLE
ibopt
ibterm
DSABLE
0
0/1
0/1
4-20
DSABLE/ENABLE
DSABLE/ENABLE
mA
ibrecyc
REF_OPT
REF_LEAK
DSABLE
DSABLE
20
20-30
35-50
0-100
PSI
PSI
%
HPDP0
HPDP100
HPDPMIN%
25
35
0
NOTE: No variables are available for CCN read or write operation.
34
Table 3 — CVD Display Data (cont)
EXAMPLE 17 — SETUP1 DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP1 .
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Comp Discharge Alert
STATUS
150-200
150-260
125-200
UNITS
DEG F
PSI
DEG F
POINT
MT_OVER
CP_OVER
CD_ALERT
DEFAULT
200
230
200
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Condenser Freeze Point
0/1
.5-2.0
0.0-40.0
2.0-5.0
–20 -35
WATER/BRINE
^F
DEG F
^F
DEG F
MEDIUM
CW_DB
ERT_TRIP
REF_OVER
CDFREEZE
WATER
1.0
33
3
34
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Water Flow Verify Time
Oil Filter Pressure Alert
Recycle Control
Recycle Restart Delta T
Recycle Shutdown Delta
0.5 - 50.0
0.5 - 50.0
0.5-5
1-15
PSI
PSI
MIN
PSI
EVAP_CUT
COND_CUT
WFLOW_T
OILFALRT
5.0
5.0
5
3
2.0-10.0
0.5-4.0
DEG F
DEG F
rcycr_dt
rcycs_dt
5
1
sp1_en
sp1_lim
sp2_ en
sp2_ lim
TC_23XL
0
245
0
245
1
Spars Alert/Alarm Enable
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
23XL Model TC Comp?
0-4
–40-245
0-4
–40-245
0-1
DEG F
DEG F
NO/YES
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 18 — SETUP2 DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP2 .
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional Dec Band
Proportional ECW Band
VFD/Slide Valve Control
VFD Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
Manual SV Temp Option
STATUS
UNITS
2-10
2-10
1-3
0/1
0.1-1.5
1-5
20-100
50-100
0-1
DSABLE/ENABLE
%
%
%
DSABLE/ENABLE
POINT
DEFAULT
sv_inc
sv_dec
sw_ecw
6.5
6.0
2
vfd_opt
vfd_gain
vfd_step
vfd_min
vfd_max
sv_opt
DSABLE
0.75
2
70
100
DSABLE
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
35
Table 3 — CVD Display Data (cont)
EXAMPLE 19 — LEAD/LAG DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight LEAD/LAG .
DESCRIPTION
Lead Lag Control
LEAD/LAG Configuration
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG % Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Optioin
STANDBY % Capacity
STANDBY Address
STATUS
0-3
UNITS
0/1
0/1
25-75
1-236
2-60
2-60
2-30
0/1
25-75
1-236
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
POINT
leadlag
leadlag
DEFAULT
0
0
loadbal
commsens
lag_per
lag_add
lagstart
lagstop
preft
stndopt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 20 — RAMP_DEM DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Motor Load Ramp % Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Motor Rated Kilowatts
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
50-9999
5-60
%
%
DSABLE/ENABLE
kW
MIN
POINT
rampslct
DEFAULT
1
dem_src
0
kw_ramp
dem_app
dem_20ma
dem_sel
motor_kw
dw_int
10
10
40
DSABLE
145
15
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 21 — TEMP_CTL DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight TMP_CTL .
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp (No Reset)
Remote Temp (Full Reset)
Degrees Reset
RESET TYPE 3
CHW Delta T (No Reset)
CHW Delta T (Full Reset)
Degrees Reset
Select/Enable Reset Type
STATUS
UNITS
POINT
DEFAULT
0/1
2-10
DSABLE/ENABLE
^F
ecw_opt
tmp_ramp
DSABLE
3
–30- 30
^F
deg_20ma
10
–40-245
–40-245
–30-30
DEG F
DEG F
^F
res_rt
res_rt
deg_rt
85
65
10
0-15
0-15
–30-30
0-3
^F
^F
^F
restd_1
restd_2
deg_chw
res_sel
10
0
5
0
36
PIC II System Functions
NOTE: Increasing either of these settings causes the slide
valve to respond more slowly than they would at a lower
setting.
The PROPORTIONAL ECW BAND can be adjusted on the
CVC display for values of 1, 2, or 3; the default setting is 2.
Increase this setting to increase slide valve response to a
change in entering chilled water temperature.
DEMAND LIMITING — The PIC II responds to the
ACTIVE DEMAND LIMIT set point by limiting the opening of
the slide valve. It compares the ACTIVE DEMAND LIMIT set
point to the DEMAND LIMIT SOURCE (either the AVERAGE
LINE CURRENT or the MOTOR KW), depending on how the
control is configured. DEMAND LIMIT SOURCE is on the
RAMP_DEM screen. The default source is the compressor
motor current.
CHILLER TIMERS — The PIC II maintains 2 runtime
clocks, known as COMPRESSOR ONTIME and SERVICE
ONTIME. COMPRESSOR ONTIME indicates the total lifetime compressor run hours. This timer can register up to
500,000 hours before the clock turns back to zero. The SERVICE ONTIME is a reset table timer that can be used to indicate the hours since the last service visit or any other event. The
time can be changed from the CVC to whatever value is desired. This timer can register up to 32,767 hours before it rolls
over to zero.
The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the chiller can be
started. START INHIBIT TIMER is displayed on the MAINSTAT screen. See the Start-Up/Shutdown/Recycle Sequence
section, page 47, for more information on this topic.
OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 24), determines when the chiller can run. Each schedule consists of
from 1 to 8 occupied or unoccupied time periods, set by the operator. The chiller can be started and run during an occupied
time period (when OCCUPIED ? is set to YES on the MAINSTAT display screen). It cannot be started or run during an unoccupied time period (when OCCUPIED ? is set to NO on the
MAINSTAT display screen). These time periods can be set for
each day of the week and for holidays. The day begins with
0000 hours and ends with 2400 hours. The default setting for
OCCUPIED ? is YES, unless an unoccupied time period is in
effect.
These schedules can be set up to follow a building’s occupancy schedule, or the chiller can be set so to run 100% of the
time, if the operator wishes. The schedules also can be bypassed by forcing the CHILLER START/STOP parameter on
the MAINSTAT screen to START. For more information on
forced starts, see Local Start-Up, page 47.
The schedules also can be overridden to keep the chiller in
an occupied state for up to 4 hours, on a one time basis. See the
Time Schedule Operation section, page 24.
Figure 22 shows a schedule for a typical office building
with a 3-hour, off-peak, cool-down period from midnight to
3 a.m., following a weekend shutdown. Holiday periods are in
an unoccupied state 24 hours per day. The building operates
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays
from 6:00 a.m. to 1:00 p.m. This schedule also includes the
Monday midnight to 3:00 a.m. weekend cool-down schedule.
NOTE: This schedule is for illustration only and is not
intended to be a recommended schedule for chiller operation.
Whenever the chiller is in the LOCAL mode, it uses Occupancy Schedule 01 (OCCPC01S). When the chiller is in the
ICE BUILD mode, it uses Occupancy Schedule 02
(OCCPC02S). When the chiller is in CCN mode, it uses Occupancy Schedule 03 (OCCPC03S).
The CCN SCHEDULE NUMBER is configured on the
NET_OPT display screen, accessed from the EQUIPMENT
NOTE: Words not part of paragraph headings and printed in all
capital letters can be viewed on the CVC (e.g., LOCAL, CCN,
RUNNING, ALARM, etc.) Words printed in both all capital
letters and italics can also be viewed on the CVC and are
parameters (CONTROL MODE ADDED EXAMPLES, etc.)
with associated values (e.g., modes, temperatures, pressures,
percentages, on, off, enable, disable, etc.).Words printed in all
capital letters and in a box represent softkeys on the CVC (e.g.,
ENTER and EXIT ). See Table 3 for examples of the type of
information that can appear on the CVC screens. Figures 17-23
give an overview of CVC operations and menus.
CAPACITY CONTROL — The PIC II controls the chiller
capacity by modulating the slide valve in response to chilled
water temperature deviation away from the CONTROL
POINT. The CONTROL POINT may be changed by a CCN
network device or is determined by the PIC II adding any active chilled water reset to the SET POINT. The PIC II uses the
PROPORTIONAL INC (Increase) BAND, PROPORTIONAL
DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water) GAIN to determine how fast or slow to
respond. CONTROL POINT may be viewed or overridden
from the MAINSTAT screen.
ECW CONTROL OPTION — If this option is enabled, the
PIC II uses the ENTERING CHILLED WATER temperature to
modulate the slide valve instead of the LEAVING CHILLED
WATER temperature. The ECW CONTROL OPTION may be
viewed on the TEMP_CTL screen, which is accessed from the
EQUIPMENT SERVICE screen.
CONTROL POINT DEADBAND — This is the tolerance
range on the chilled water/brine temperature control point. If
the water temperature goes outside the CHILLED WATER
DEADBAND, the PIC II opens or closes the slide valve until
the temperature is within tolerance. The PIC II may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED
WATER DEADBAND may be viewed or modified on the
SETUP1 screen, which is accessed from the EQUIPMENT
SERVICE table.
For example, a 1º F (0.6º C) deadband setting controls the
water temperature within ±0.5º F (0.3º C) of the control point.
This may cause frequent slide valve movement if the chilled
water load fluctuates frequently. A value of 1º F (0.6º C) is the
default setting.
PROPORTIONAL BANDS AND GAIN — Proportional
band is the rate at which the slide valve position is corrected in
proportion to how far the chilled water/brine temperature is
from the control point. Proportional gain determines how
quickly the slide valve reacts to how quickly the temperature is
moving from the CONTROL POINT. The proportional bands
and gain may be viewed or modified from the SETUP2 screen,
which is accessed from the EQUIPMENT SERVICE table.
The Proportional Band — There are two response modes, one
for temperature response above the control point, the other for
the response below the control point.
The temperature response above the control point is called
the PROPORTIONAL INC BAND, and it can slow or quicken
slide valve response to chilled water/brine temperatures above
the DEADBAND. The PROPORTIONAL INC BAND can be
adjusted from a setting of 2 to 10; the default setting is 6.5.
The response below the control point is called the
PROPORTIONAL DEC BAND, and it can slow or quicken the
slide valve response to chilled water temperature below the
deadband plus the control point. The PROPORTIONAL DEC
BAND can be adjusted on the CVC from a setting of 2 to 10.
The default setting is 6.0.
37
Default Screen Freeze — When the chiller is in an
alarm state, the default CVC display “freezes,” that is, it stops
updating. The first line of the CVC default screen displays a
primary alarm message; the second line displays a secondary
alarm message.
The CVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If the
value in alarm is one normally displayed on the default screen,
it flashes between normal and reverse video. The CVC default
screen remains frozen until the condition that caused the alarm
is remedied by the operator.
Knowledge of the operating state of the chiller at the time an
alarm occurs is useful when troubleshooting. Additional chiller
information can be viewed on the status screens and the
ISM_HIST screen. Troubleshooting information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the alarm, the operator should
read both the primary and secondary default screen messages,
as well as the alarm history. The primary message indicates the
most recent alarm condition. The secondary message gives
more detail on the alarm condition. Since there may be more
than one alarm condition, another alarm message may appear
after the first condition is cleared. Check the ALARM HISTORY screen for additional help in determining the reasons for the
alarms. Once all existing alarms are cleared (by pressing the
RESET softkey), the default CVC display returns to normal
operation.
CONFIGURATION table. See Table 3, Example 14. SCHEDULE NUMBER can be changed to any value from 03 to 99. If
this number is changed on the NET_OPT screen, the operator
must go to the ATTACH TO NETWORK DEVICE screen to
upload the new number into the SCHEDULE screen. See
Fig. 21.
Safety Controls — The PIC II monitors all safety control
inputs and, if required, shuts down the chiller or limits the slide
valve to protect the chiller from possible damage from any of
the following conditions:
• high motor winding temperature
• high discharge temperature
• low discharge superheat temperature TC (frame 1 and 2)
compressor chillers*
• low oil pressure
• low cooler refrigerant temperature
• condenser high pressure or low pressure
• inadequate water/brine cooler and condenser flow
• high, low, or loss of voltage
• ground fault (option)
• high oil filter pressure drop
• low oil level
• voltage imbalance
• current imbalance
• excessive motor acceleration time
• excessive starter transition time
• lack of motor current signal
• excessive motor amps
• excessive compressor stall
• temperature sensor and transducer faults
Ramp Loading — The ramp loading control slows
down the rate at which the compressor loads up. This control
can prevent the compressor from loading up during the short
period of time when the chiller is started and the chilled water
loop has to be brought down to CONTROL POINT. This helps
reduce electrical demand charges by slowly bringing the
chilled water to CONTROL POINT.
There are two methods of ramp loading with the PIC II.
Ramp loading can be based on chilled water temperature or on
motor load. Either method is selected from the RAMP__DEM
screen.
1. Temperature ramp loading (TEMP PULLDOWN DEG/
MIN) limits the degrees per minute rate at which either
leaving chilled water or entering chilled water temperature decreases. This rate is configured by the operator
on the TEMP_CTL screen. The lowest temperature
ramp rate will also be used if chiller power has been
off for 3 hours or more (even if the motor ramp load is
selected as the ramp loading method.
2. Motor load ramp loading (LOAD PULLDOWN) limits
the degrees per minute rate at which the compressor
motor current or compressor motor load increases. The
LOAD PULLDOWN rate is configured by the operator
on the RAMP_DEM screen in amps or kilowatts.
If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED KILOWATTS must be entered (information found on the chiller Requisition form).
The TEMP PULLDOWN DEG/MIN may be viewed or
modified on the TEMP_CTL screen which is accessed from
the EQUIPMENT SERVICE screen. PULLDOWN RAMP
TYPE, DEMAND LIMIT SOURCE, and MOTOR LOAD
RAMP %/MIN may be viewed or modified on the
RAMP_DEM screen.
Capacity Override (Table 5) — Capacity overrides
can prevent some safety shutdowns caused by exceeding the
motor amperage limit, refrigerant low temperature safety limit,
motor high temperature safety limit, and condenser high pressure limit. In all cases, there are 2 stages of compressor slide
valve control.
*Superheat is the difference between saturation temperature and sensible temperature. The high discharge temperature safety measures
only sensible temperature.
Starter faults or optional protective devices within the starter
can shut down the chiller. The protective devices you have for
your application depend on what options were purchased.
If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart
If the PIC II control initiates a safety shutdown, it displays
the reason for the shutdown (the fault) on the CVC display
screen along with a primary and secondary message, energizes
an alarm relay in the starter, and blinks the alarm light on the
control panel. The alarm is stored in memory and can be
viewed on the ALARM HISTORY and ISM_HIST screens on
the CVC, along with a message for troubleshooting. If the safety shutdown was also initiated by a fault detected in the motor
starter, the conditions at the time of the fault will be stored in
ISM_HIST.
To give more precise information or warnings on the chiller’s operating condition, the operator can define alert limits on
various monitored inputs. Safety contact and alert limits are defined in Table 4. Alarm and alert messages are listed in the
Troubleshooting Guide section, page 76.
Shunt Trip (Option) — The function of the shunt trip
option on the PIC II is to act as a safety trip. The shunt trip is
wired from an output on the ISM to a shunt trip equipped motor circuit breaker. If the PIC II tries to shut down the compressor using a normal shutdown procedure but is unsuccessful for
30 seconds, the shunt trip output is energized and causes the
circuit breaker to trip off. If ground fault protection has been
applied to the starter, the ground fault trip also energizes the
shunt trip to trip the circuit breaker. Protective devices in the
starter can also energize the shunt trip. The shunt trip feature
can be tested using the Control Test feature.
38
Oil Sump Temperature Control TC (Frame 1
and 2) Chillers Only — The oil sump temperature con-
1. The slide is prevented from closing further, and the
status line on the CVC indicates the reason for the
override.
2. The slide valve is opened until the condition decreases
to below the first step set point. Then the slide valve is
normal capacity control. Whenever the motor current
demand limit set point (ACTIVE DEMAND LIMIT) is
reached, it activates a capacity override, again, with a
2-step process. Exceeding 110% of the rated load amps
for more than 30 seconds will initiate a safety
shutdown.
trol is regulated by the PIC II using the oil heater relay when
the chiller is shut down. The oil heater relay is energized whenever the chiller compressor is off, and the oil sump temperature
is less than 140 F (60 C) or sump temperature is less than the
cooler refrigerant temperature plus 53 F (29.4 C). The heater is
then turned off when the oil sump temperature is:
1. More than 150 F (71 C).
2. The sump temperature is more than 142 F (61.1 C) and
more than the cooler refrigerant temperature plus 55 F
(12.8 C). (The heater is always off during start-up or
when the compressor is running.)
Low Discharge Temperature Control — Low discharge superheat is protective limit for R-22, Frame 1 and 2 TC
compressor chillers only. Monitoring of discharge superheat is
initiated 30 minutes after a completed start-up. If the discharge
superheat, calculated as COMPRESSOR DISCHARGE TEMPERATURE – CONDENSER REFRIGERANT TEMPERATURE, falls below 20 F (11.1 C) for 10 consecutive minutes, a
“low discharge superheat” non-recycle shutdown alarm 240,
will occur.
All oil filter isolation valves should always be left open,
except when changing the oil or oil filter as defined in
Changing Oil and Oil Filter section, page 73.
Table 4 — Protective Safety Limits and Control Settings
MONITORED PARAMETER
TEMPERATURE SENSOR OUT OF RANGE
PRESSURE TRANSDUCERS OUT OF RANGE
LIMIT
–40 to 245 F (–40 to 118.3 C)
0.06 to 0.98 Voltage Ratio
COMPRESSOR DISCHARGE TEMPERATURE
MOTOR WINDING TEMPERATURE
LOW DISCHARGE SUPERHEAT
>220 F (104.4 C)
>220 F (104.4 C)
Oil sump temp — condenser refrigerant
temp is less than 20 F (11.1 C). Only applicable to TC (frame 1 and 2) chillers.
Oil pressure transducer less than condenser pressure — oil filter pressure alert
starting 40 seconds after motor current
> 10% and oil pressure verified
Oil pressure transducer less than condenser pressure — 110 psi (758 kPa)
starting 40 seconds after motor current
> 10% and oil pressure verified
<Required oil pressure starting 120 seconds after motor current > 10%
OIL PRESSURE
— Dirty Oil Filter
— Low Oil Pressure
OIL LEVEL
Discrete
EVAPORATOR REFRIGERANT
TEMPERATURE
<33 F (FOR WATER CHILLING) (0.6°C)
TRANSDUCER VOLTAGE
CONDENSER PRESSURE
— Switch
— Control
LINE VOLTAGE
— High
— Low
— Single-Cycle
COMPRESSOR MOTOR LOAD
STARTER ACCELERATION TIME
(Determined by inrush current going below
100% compressor motor load)
STARTER TRANSITION
CONDENSER FREEZE PROTECTION
<EVAP REFRIG TRIPPOINT (set point
adjustable from 0 to 40 F [–18 to 4 C] for
brine chilling)
<4.5 vdc> 5.5 vdc
263 ± 5 psig (1813 ± 34 kPa), reset at
180 ± 7 psig (1241 ± 48 kPa)
260 psig (1793 kPa)
>150% for 1 second or >120% for
10 seconds
<85% for 10 seconds or ≤80 for 5 seconds
or <75% for 1 second
<50% for one cycle
>110% for 30 seconds
<5% with compressor running
<5% with compressor off
>45 seconds
>10 seconds
>20 seconds
Energizes condenser pump relay if
condenser refrigerant temperature or
entering water temperature is below the
configured condenser freeze point temperature. Deenergizes when the temperature
is 5 F (3 C) above condenser freeze point
temperature.
39
APPLICABLE COMMENTS
Must be outside range for 2 seconds.
Must be outside range for 3 seconds.
Ratio = Input Voltage ÷ Voltage Reference
Preset, alert setting configurable.
Preset, alert setting configurable.
Preset, monitored 30 minutes after start-up
completion must be outside range for
10 consecutive minutes.
Must be outside range for 3 seconds; oil
pressure alert setting configurable from 1 to
15 psi (6.9 to 103 kPa) on SETUP 1 table.
Must be outside range for 3 seconds.
Minimum required oil pressure based on
system pressure ratio is between 7 psi
(48 kPa) and 20 psi (137.9 kPa)
Preset: must be outside range for
15 seconds.
Preset, configurable chilled medium for
water (SETUP1 table).
Configure chilled medium for brine
(SETUP1 table). Adjust EVAP REFRIG
TRIPPOINT for proper cutout.
Preset
Preset
Preset
Preset, based on transformed line voltage
to ISM. Also monitored at CVC and CCM
power input.
Preset
Preset
Preset
For chillers with reduced voltage mechanical
and solid-state starters.
For chillers with full voltage starters
(Configures on ISM_CONFIG table).
Reduced voltage starters only.
CONDENSER FREEZE POINT configured
in SETUP1 table with a default setting of
34 F (1 C).
Table 5 — Capacity Overrides Table Capacity Overrides
OVERRIDE
CAPACITY CONTROL
FIRST STAGE SET POINT
OVERRIDE
TERMINATION
Value
Value
>Override
Set Point
+10° F (6° C)
<Override
Set Point
View/Modify
on CVC Screen
Default
Value
SETUP1
230 psig
(1586 kPa)
SETUP1
3° F (1.6° C)
2° to 5° F
(1° to 3° C)
≤Trippoint
+ Override
∆T - 1° F (0.56° C)
>Trippoint
+ Override
∆T+2° F (1.2° C)
COMPRESS
Automatic
–10 to +10 sec
None
Release of
Manual Control
MOTOR LOADACTIVE DEMAND LIMIT
MAINSTAT
100%
40 to 100%
≥5% of
Set Point
2% Lower
Than Set Point
DISCHARGE SUPERHEAT
FRAME 1 AND 2 R-22 ONLY
OVERRIDE
Calculated Minimum
Superheat For
Conditions
–20 to 999
2° F (1.1° C)
Below Calculated
Superheat
1° F (0.56° C)
Above Calculated
Minimum Superheat
HIGH CONDENSER
PRESSURE
REFRIGERANT
OVERRIDE DELTA
TEMPERATURE
(Low refrigerant temperature)
MANUAL SLIDE VALVE
LOAD/UNLOAD
Remote Start/Stop Controls — A remote device,
such as a timeclock that uses a set of contacts, may be used to
start and stop the chiller. However, the device should not be
programmed to start and stop the chiller in excess of 2 or
3 times every 12 hours. If more than 8 starts in 12 hours (the
STARTS IN 12 HOURS parameter on the MAINSTAT screen)
occur, an excessive starts alarm displays, preventing the chiller
from starting. The operator must press the RESET softkey on
the CVC to override the starts counter and start the chiller. If
the chiller records 12 starts (excluding recycle starts) in a sliding 12-hour period, it can be restarted only by pressing the
RESET softkey followed by the LOCAL or CCN softkey.
This ensures that, if the automatic system is malfunctioning,
the chiller will not repeatedly cycle on and off. If the automatic
restart after a power failure option (AUTO RESTART OPTION
on the OPTIONS screen) is not activated when a power failure
occurs, and if the remote contact is closed, the chiller will indicate an alarm because of the loss of voltage.
Configurable
Range
150 to 260 psig
(1032 to
1793 kPa)
SECOND STAGE
SET POINT
or configured for 0 to 5 vdc by setting switch 1 at the OFF position. The output of the refrigerant leak detector is displayed as
REFRIGERANT LEAK SENSOR on the MAINSTAT screen.
For a 0 to 5 vdc input, 0 vdc input represents 4 mA displayed
and 5 vdc input represents 20 mA displayed.
Condenser Pump Control — The chiller will monitor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure becomes too high while the compressor is shut down. The condenser pressure override (COND PRESS OVERRIDE) parameter is used to determine this pressure point. COND PRESS
OVERRIDE is found in the SETUP1 display screen, which is
accessed from the EQUIPMENT SERVICE table. The default
value is 230 psig (862 kPa).
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, and the entering condenser
water temperature (ENTERING CONDENSER WATER) is less
than 115 F (46 C), the condenser pump will energize to try to
decrease the pressure. The pump will turn off when the condenser pressure is 3.5 psi (24.1 kPa) less than the pressure override or when the condenser refrigerant temperature (CONDENSER REFRIG TEMP) is within 3º F (1.7º C) of the entering condenser water temperature (ENTERING CONDENSER
WATER).
The contacts for remote start are wired into the starter at terminal strip J2, terminals 5 and 6 on the ISM. See the certified
drawings for further details on contact ratings. The contacts
must have 24 vac rating.
Condenser Freeze Prevention — This control algorithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay. The PIC II controls the pump and, by
starting it, helps to prevent the water in the condenser from
freezing. The PIC II can perform this function whenever the
chiller is not running except when it is either actively in pumpdown or in pumpdown/lockout with the freeze prevention
disabled.
When the CONDENSER REFRIG TEMP is less than or
equal to the CONDENSER FREEZE POINT, the CONDENSER WATER PUMP is energized until the CONDENSER
REFRIG TEMP is greater than the CONDENSER FREEZE
POINT plus 5º F (2.7º C) and the ENTERING CONDENSER
WATER TEMPERATURE is greater than or equal to the
CONDENSER FREEZE POINT. An alarm is generated if the
chiller is in PUMPDOWN mode and the pump is energized.
An alert is generated if the chiller is not in PUMPDOWN
mode and the pump is energized. If the chiller is in RECYCLE
SHUTDOWN mode, the mode will transition to a non-recycle
shutdown.
Spare Safety Inputs — Normally closed (NC) discrete
inputs for additional field-supplied safeties may be wired to the
spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) The opening
of any contact will result in a safety shutdown and a display on
the CVC. Refer to the certified drawings for safety contact
ratings.
Analog temperature sensors may also be added to the module (SPARE TEMP #1 and #2). The analog temperature sensors may be configured to cause an alert or alarm on the CCN
network. The alert will not shut the chiller down. Configuring
for alarm state will cause the chiller to shut down.
Spare Safety Alarm Contacts — One set of alarm
contacts is provided in the starter. The contact ratings are provided in the certified drawings. The contacts are located on
terminal strip JP, terminals 15 and 16.
Refrigerant Leak Detector — An input is available
on the CCM module [terminal J15-5 (–) and J5-6 (+)] for a
refrigerant leak detector. Enabling REFRIGERANT LEAK
OPTION (OPTIONS screen) will allow the PIC II controls to
go into an alarm state at a user configured level (REFRIGERANT LEAK ALARM mA). The input is configured for 4 to
20 mA by setting the DIP switch 1 on SW2 at the ON position,
Tower Fan Relay Low and High — Low condenser
water temperature can cause the chiller to shut down when refrigerant temperature is low. The tower fan relays, located in
the starter, are controlled by the PIC II to energize and deenergize as the pressure differential between cooler and condenser
40
The CVC default screen indicates when the chilled water reset is active. TEMPERATURE RESET on the MAINSTAT
screen indicates the amount of reset. The CONTROL POINT
will be determined by adding the TEMPERATURE RESET to
the SETPOINT.
To activate a reset type, access the TEMP_CTL screen and
input all configuration information for that reset type. Then, input the reset type number (1, 2, or 3) in the SELECT/ENABLE
RESET TYPE input line.
RESET TYPE 1: 4 to 20 mA (0 to 5 vdc) TEMPERATURE
RESET — Reset Type 1 is an automatic chilled water temperature reset based on a remote temperature sensor input configured for either an externally powered 4 to 20 mA or a 0 to
5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C) of
automatic reset to the chilled water set point.
The auto, chilled water reset is hardwired to terminals
J5-3 (–) and J5-4 (+) on the CCM. Switch setting number 2 on
SW2 will determine the type of input signal. With the switch
set at the ON position the input is configured for an externally
powered 4 to 20 mA signal. With the switch in the OFF position the input is configured for an external 0 to 5 vdc signal.
RESET TYPE 2: REMOTE TEMPERATURE RESET —
Reset Type 2 is an automatic chilled water temperature reset
based on a remote temperature sensor input signal. Reset Type
2 permits ±30º F (±16º C) of automatic reset to the set point
based on a temperature sensor wired to the CCM module (see
wiring diagrams or certified drawings). The temperature sensor
must be wired to terminal J4-13 and J4-14.
To configure Reset Type 2, enter the temperature of the remote sensor at the point where no temperature reset will occur
(REMOTE TEMP [NO RESET]). Next, enter the temperature
at which the full amount of reset will occur (REMOTE TEMP
[FULL RESET]). Then, enter the maximum amount of reset required to operate the chiller (DEGREES RESET). Reset Type 2
can now be activated.
RESET TYPE 3 — Reset Type 3 is an automatic chilled water
temperature reset based on cooler temperature difference.
Reset Type 3 adds ±30º F (±16º C) based on the temperature difference between the entering and leaving chilled
water temperature.
To configure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving
chilled water) at which no temperature reset occurs (CHW
DELTA T [NO RESET]). This chilled water temperature difference is usually the full design load temperature difference.
Next, enter the difference in chilled water temperature at which
the full amount of reset occurs (CHW DELTA T [FULL
RESET]). Finally, enter the amount of reset (DEGREES
RESET). Reset Type 3 can now be activated.
vessels changes. This prevents low condenser water temperature and maximizes chiller efficiency. The tower fan relay can
only accomplish this if the relay has been added to the cooling
tower temperature controller.
The tower fan relay low is turned on whenever the condenser water pump is running, flow is verified, and the difference
between cooler and condenser pressure is more than 30 psid
(207 kPad) for entering condenser water temperature greater
than 65 F (18.3 C).
The tower fan relay low is turned off when the condenser
pump is off, flow is stopped, or the cooler refrigerant temperature is less than the override temperature for ENTERING CONDENSER WATER temperature less than 62 F (16.7 C), or the
differential pressure is less than 25 psid (172.4 kPad) for entering condenser water less than 80 F (27 C).
The tower fan relay high is turned on whenever the condenser water pump is running, flow is verified and the difference between cooler and condenser pressure is more than
35 psid (241.3 kPa) for entering condenser water temperature
greater than the TOWER FAN HIGH SETPOINT (SETPOINT
menu, default 75 F [23.9 C]).
The tower fan relay high is turned off when the condenser
pump is off, flow is stopped, or the cooler refrigerant temperature is less than the override temperature and ENTERING
CONDENSER WATER is less than 70 F (21.1 C), or the difference between cooler and condenser pressure is less than
28 Psid (193 kPa), or ENTERING CONDENSER WATER temperature is less than TOWER FAN HIGH SETPOINT minus 3 F
(–16.1 C).
The TOWER FAN RELAY LOW and HIGH parameters
are accessed from the STARTUP screen.
IMPORTANT: A field-supplied water temperature control system for condenser water should be installed. The
system should maintain the leaving condenser water
temperature at a temperature that is 20º F (11º C) above
the leaving chilled water temperature.
The tower fan relay control is not a substitute for a condenser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.
Auto. Restart After Power Failure — This option
may be enabled or disabled and may be viewed or modified on
the OPTIONS screen, which is accessed from the EQUIPMENT CONFIGURATION table. If the AUTO. RESTART
option is enabled, the chiller will start up automatically after a
power failure has occurred (after a single cycle dropout; low,
high, or loss of voltage; and the power is within ±10% of normal). The 15- and 3-minute inhibit timers are ignored during
this type of start-up.
When power is restored after the power failure, a power
failure restart will be enabled and the control allowed to
AUTORESTART the chiller, starting with the chilled water
pump(s), if start-up conditions are met.
If power to the CVC module has been off for more than
3 hours or the timeclock has been set for the first time, start the
compressor with the slowest temperature-based ramp load rate
possible in order to minimize oil foaming.
Demand Limit Control Option — The demand limit
control option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA or 0 to 5 vdc signal from an energy
management system (EMS). The option is set up on the
RAMP_DEM screen. When enabled, 4 mA is the 100%
demand set point with an operator-configured minimum
demand at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-5 (–)
and J5-6 (+) on the CCM. Switch setting number 1 on SW2
will determine the type of input signal. With the switch set at
the ON position the input is configured for an externally powered 4 to 20 mA signal. With the switch in the OFF position the
input is configured for an external 0 to 5 vdc signal.
Hot Gas Bypass (Optional) Algorithm (See
Fig. 24 and 25) — If a hot gas bypass solenoid valve is
Water/Brine Reset — Three types of chilled water or
brine reset are available and can be viewed or modified on the
TEMP_CTL screen, which is accessed from the EQUIPMENT
SERVICE table.
present, and the hot gas bypass option on the OPTIONS table is
enabled, this operator configurable feature can determine if
load conditions are too low for the compressor and then take
corrective action.
41
The algorithm first determines if corrective action is necessary. This is done by checking two sets of operator configured
data points, which are the MINIMUM and the MAXIMUM
Load Points, (T1/P1;T2/P2). These points have default settings
for each type of refrigerant, HCFC-22 or HFC-134a, as defined
on the OPTIONS table, and on Table 3. These settings and the
algorithm logic are graphically displayed in Fig. 24 and 25.
The two sets of load points on this graph (default settings are
shown) describe a line which the algorithm uses to activate the
hot gas bypass. Whenever the temperature difference between
the entering and leaving chilled water is on the left side of the
line on the graph (as defined by the MINIMUM and MAXIMUM Load Points), the algorithm will then energize the hot
gas bypass valve to falsely load the chiller and prevent displacement of oil. If the actual values are on the right side of the
line, the algorithm takes no action.
HEAD PRESSURE OUTPUT REFERENCE (See
Fig. 26) — The PIC II control outputs a 4 to 20 mA signal for
the configurable Delta P (condenser pressure – evaporator
pressure) reference curve shown in Fig. 26. The Delta P at
100% (default at 35 psi). Delta P at 0% (default at 25 psi) and
Minimum Reference Point are configurable in the EQUIPMENT SERVICE-OPTIONS table. When configuring this output, ensure that minimum requirements for oil pressure and
proper condenser FLASC orifice performance are maintained.
LEGEND
∆P
—
∆T
ECW
—
—
LCW
—
HGBP
—
DEFAULT VALUES:
Condenser PressureCooler Pressure
ECW-LCW
Entering Chilled
Water Temperature
Leaving Chilled
Water Temperature
Hot Gas Bypass
POINT
∆T1
∆P1
∆T2
∆P2
HCFC-22
2.5
50
10
200
HFC-134a
2.5
30
10
170
Fig. 24 — 23XL Hot Gas Bypass (English)
Lead/Lag Control — The lead/lag control system automatically starts and stops a lag or second chiller in a 2-chiller
water system. A third chiller can be added to the lead/lag system as a standby chiller to start up in case the lead or lag chiller
in the system has shut down during an alarm condition and additional cooling is required.Refer to Fig. 20 and 21 for menu,
table, and screen selection information.
NOTE: The lead/lag function can be configured on the LEADLAG screen, which is accessed from the SERVICE menu and
EQUIPMENT SERVICE table. See Table 3, Example 19.
Lead/lag status during chiller operation can be viewed on the
LL_MAINT display screen, which is accessed from the SERVICE menu and CONTROL ALGORITHM STATUS table.
See Table 3, Example 11.
Lead/Lag System Requirements:
• all chillers in the system must have software capable of
performing the lead/lag function
• water pumps MUST be energized from the PIC II
controls
• water flows should be constant
• the CCN time schedules for all chillers must be identical
Operation Features:
• 2 chiller lead/lag
• addition of a third chiller for backup
• manual rotation of lead chiller
• load balancing if configured
• staggered restart of the chillers after a power failure
• chillers may be piped in parallel or in series chilled
water flow
COMMON POINT SENSOR INSTALLATION — Lead/
lag operation does not require a common chilled water point
sensor. Common point sensors (Spare Temp #1 and #2) can be
added to the CCM module, if desired. Spare Temp #1 and #2
are wired to plug J4 terminals 25-26 and 27-28 (J4 lower,
respectively).
NOTE: If the common point sensor option is chosen on a
chilled water system, each chiller should have its own common
point sensor installed. Each chiller uses its own common point
sensor for control when that chiller is designated as the lead
chiller. The PIC II cannot read the value of common point sensors installed on the other chillers in the chilled water system.
DEFAULT VALUES:
LEGEND
∆P
∆T
ECW
LCW
HGBP
—
Condenser PressureCooler Pressure
— ECW-LCW
— Entering Chilled
Water Temperature
— Leaving Chilled
Water Temperature
— Hot Gas Bypass
POINT
∆T1
∆P1
∆T2
∆P2
HCFC-22
1.4
345
5.6
1379
HFC-134a
1.4
207
5.6
1172
Fig. 25 — 23XL Hot Gas Bypass (SI)
DELTA P
AT 100%
DELTA P
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 0%
0 mA 2 mA 4 mA
(0%)
4 T0 20 mA OUTPUT
Fig. 26 — Head Pressure Output
Reference Control
42
20 mA
(100%)
lead chiller monitors conditions and evaluates whether the capacity has been reduced enough for the lead chiller to sustain
the system alone. If the capacity is reduced enough for the lead
chiller to sustain the CONTROL POINT temperatures alone,
then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead chiller’s place as the lead chiller, and the standby chiller serves as
the lag chiller.
If the configured lead chiller does not complete the start-up
before the PRESTART FAULT TIMER (a user-configured value) elapses, then the lag chiller starts and the lead chiller shuts
down. The lead chiller then monitors the start request from the
acting lead chiller. The PRESTART FAULT TIMER is initiated
at the time of a start request. The PRESTART FAULT TIMER
provides a timeout if there is a prestart alert condition that prevents the chiller from starting in a timely manner. The PRESTART FAULT TIMER parameter is on the LEAD-LAG
screen, which is accessed from the EQUIPMENT SERVICE
table of the SERVICE menu.
If the lag chiller does not achieve start-up before the PRESTART FAULT TIMER elapses, the lag chiller stops, and the
standby chiller is requested to start, if configured and ready.
Standby Chiller Configuration and Operation — A chiller is
designated as a standby chiller when its LEAD/LAG CONFIGURATION value on the LEADLAG screen is set to “3.” The
standby chiller can operate as a replacement for the lag chiller
only if one of the other two chillers is in an alarm (*) condition
(as shown on the CVC panel). If both lead and lag chillers are
in an alarm (*) condition, the standby chiller defaults to operate
in CCN mode, based on its configured occupancy schedule and
remote contacts input.
Lag Chiller Start-Up Requirements — Before the lag chiller
can be started, the following conditions must be met:
1. Lead chiller ramp loading must be complete.
2. Lead chilled water temperature must be greater than
the CONTROL POINT temperature (see the MAINSTAT screen) plus 1/2 the CHILLED WATER DEADBAND temperature (see the SETUP1 screen).
NOTE: The chilled water temperature sensor may be
the leaving chilled water sensor, the return water sensor, the common supply water sensor, or the common
return water sensor, depending on which options are
configured and enabled.
3. Lead chiller ACTIVE DEMAND LIMIT (see theMAINSTAT screen) value must be greater than 95% of full
load amps.
4. Lead chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN on the TEMP_CTL screen) of the
chilled water temperature is less than 0.5º F (0.27º C)
per minute.
5. The lag chiller status indicates it is in CCN mode and
is not in an alarm condition. If the current lag chiller is
in an alarm condition, the standby chiller becomes the
active lag chiller, if it is configured and available.
6. The configured LAG START TIMER entry has elapsed.
The LAG START TIMER starts when the lead chiller
ramp loading is completed. The LAG START TIMER
entry is on the LEADLAG screen, which is accessed
from the EQUIPMENT SERVICE table of the
SERVICE menu.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flashing
next to the point value on the STATUS table). The PIC II
control then monitors the lag chiller for a successful start. If the
lag chiller fails to start, the standby chiller, if configured is
started.
If leaving chilled water control (ECW CONTROL OPTION
is set to 0 [DSABLE], TEMP_CTL screen) and a common
point sensor is desired (COMMON SENSOR OPTION in
LEADLAG screen selected as 1) then the sensor is wired in
Spare Temp #1 position on the CCM.
If the entering chilled water control option (ECW CONTROL OPTION) is enabled (configured in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM.
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the leaving chilled water sensor of the upstream chiller must be moved
into the leaving chilled water pipe of the downstream chiller.
If return chilled water control is required on chillers piped in
series, the common point return chilled water sensor should be
installed. If this sensor is not installed, the return chilled water
sensor of the downstream chiller must be relocated to the return
chilled water pipe of the upstream chiller.
To properly control the common supply point temperature
sensor when chillers are piped in parallel, the water flow
through the shutdown chillers must be isolated so no water bypass around the operating chiller occurs. The common point
sensor option must not be used if water bypass around the operating chiller is occurring.
CHILLER COMMUNICATION WIRING — Refer to the
chiller’s Installation Instructions, Carrier Comfort Network
Interface section for information on chiller communication
wiring.
LEAD/LAG OPERATION — The PIC II not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements are not met. The lead/lag option only operates when the chillers are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.
Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its LEAD/
LAG CONFIGURATION value on the LEADLAG
screen is set to “1.”
• A chiller is designated the lag chiller when its LEAD/
LAG CONFIGURATION value is set to “2.”
• A chiller is designated as a standby chiller when its
LEAD/LAG CONFIGURATION value is set to “3.”
• A value of “0” disables the lead/lag designation of a
chiller.
To configure the LAG ADDRESS value on the LEADLAG
screen, always enter the address of the other chiller on the system. For example, if you are configuring chiller A, enter the address for chiller B as the lag address. If you are configuring
chiller B, enter the address for chiller A as the lag address. This
makes it easier to rotate the lead and lag chillers.
If the address assignments in the LAG ADDRESS and
STANDBY ADDRESS parameters conflict, the lead/lag function is disabled and an alert (!) message displays. For example,
if the LAG ADDRESS matches the lead chiller’s address, the
lead/lag will be disabled and an alert (!) message displayed.
The lead/lag maintenance screen (LL_MAINT) displays the
message ‘INVALID CONFIG’ in the LEAD/LAG: CONFIGURATION and CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and remote
start contact inputs. After completing start-up and ramp loading, the PIC II evaluates the need for additional capacity. If additional capacity is needed, the PIC II initiates the start-up of
the chiller configured at the LAG ADDRESS. If the lag chiller
is faulted (in alarm) or is in the OFF or LOCAL modes, the
chiller at the STANDBY ADDRESS (if configured) is requested
to start. After the second chiller is started and is running, the
43
the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chiller’s compressor motor load value MOTOR PERCENT
KILOWATTS or AVERAGE LINE CURRENT on the MAINSTAT screen). This value has limits of 40% to 100%. When the
lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL
POINT must be modified to a value of 3º F (1.67º C) less than
the lead chiller’s CONTROL POINT value. If the LOAD BALANCE OPTION is disabled, the ACTIVE DEMAND LIMIT
and the CONTROL POINT are forced to the same value as the
lead chiller.
AUTO. RESTART AFTER POWER FAILURE — When an
auto. restart condition occurs, each chiller may have a delay
added to the start-up sequence, depending on its lead/lag configuration. The lead chiller does not have a delay. The lag chiller has a 45-second delay. The standby chiller has a 90-second
delay. The delay time is added after the chiller water flow is
verified. The PIC II ensures adequate time for the slide valve to
unload. After the slide valve unload timer (start-up screen) has
expired, the 45 and 90 second delays for The lag and standby
chillers occurs prior to energizing 1CR. The normal start-up sequence then continues. The auto. restart delay sequence occurs
whether the chiller is in CCN or LOCAL mode and is intended
to stagger the compressor motor starts. Preventing the motors
from starting simultaneously helps reduce the inrush demands
on the building power system.
Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller compressor motor average line current or
load value (MOTOR PERCENT KILOWATTS on the
MAINSTAT screen) is less than the lead chiller percent capacity.
NOTE: Lead chiller percent capacity = 115 — LAG
PERCENT CAPACITY. The LAG PERCENT CAPACITY parameter is on the LEADLAG screen, which is
accessed from the EQUIPMENT SERVICE table on
the SERVICE menu.
2. The lead chiller chilled water temperature is less than
the CONTROL POINT temperature (see the MAINSTAT screen) plus the CHILLED WATER DEADBAND temperature (see the SETUP1 screen).
3. The configured LAG STOP TIME entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
chilled water temperature is less than the chilled water
CONTROL POINT plus 1/2 of the CHILLED WATER
DEADBAND and the lead chiller compressor motor
load (MOTOR PERCENT KILOWATT or AVERAGE
LINE CURRENT on the MAINSTAT screen) is less
than the lead chiller percent capacity.
NOTE: Lead chiller percent capacity = 115 — LAG PERCENT CAPACITY. The LAG PERCENT CAPACITY parameter is on the LEADLAG screen, which is accessed from the
EQUIPMENT SERVICE table on the SERVICE menu.
FAULTED CHILLER OPERATION — If the lead chiller
shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when the lead chiller is also
in alarm, the standby chiller reverts to a stand-alone CCN
mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
the CVC panel), press the RESET softkey to clear the alarm.
The chiller is placed in CCN mode. The lead chiller communicates and monitors the RUN STATUS of the lag and standby
chillers. If both the lag and standby chillers are running, the
lead chiller does not attempt to start and does not assume the
role of lead chiller until either the lag or standby chiller shuts
down. If only one chiller is running, the lead chiller waits for a
start request from the operating chiller. When the configured
lead chiller starts, it assumes its role as lead chiller.
Ice Build Control — The ice build control option automatically sets the CONTROL POINT of the chiller to a temperature that allows ice building for thermal storage.
NOTE: For ice build control to operate properly, the PIC II
must be in CCN mode.
NOTE: See Fig. 20 and 21 for more information on ice buildrelated menus.
The PIC II can be configured for ice build operation.
• From the SERVICE menu, access the EQUIPMENT
SERVICE table. From there, select the OPTIONS screen
to enable or disable the ICE BUILD OPTION. See
Table 3, Example 16.
• The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed from the PIC II
main menu. See Table 3, Example 8.
• The ice build schedule can be viewed or modified from
the SCHEDULE table. From this table, select the ice
build schedule (OCCPC02S) screen. See Fig. 22 and the
section on Time Schedule Operation, page 24, for more
information on modifying chiller schedules.
The ice build time schedule defines the period(s) during
which ice build is active if the ice build option is enabled. If the
ice build time schedule overlaps other schedules, the ice build
time schedule takes priority. During the ice build period, the
CONTROL POINT is set to the ICE BUILD SETPOINT for
temperature control. The ICE BUILD RECYCLE and ICE
BUILD TERMINATION parameters, accessed from the
OPTIONS screen, allow the chiller operator to recycle or terminate the ice build cycle. The ice build cycle can be configured to terminate if:
• the ENTERING CHILLED WATER temperature is less
than the ICE BUILD SETPOINT. In this case, the operator sets the ICE BUILD TERMINATION parameter to 0
on the OPTIONS screen.
• the REMOTE CONTACT inputs from an ice level indicator are opened. In this case, the operator sets the ICE
BUILD TERMINATION parameter to 1 on the
OPTIONS screen.
• the chilled water temperature is less than the ice build
set point and the remote contact inputs from an ice level
indicator are open. In this case, the operator sets the
ICE BUILD TERMINATION parameter to 2 on the
OPTIONS screen.
• the end of the ice build time schedule has been reached.
If the lag chiller is the only chiller running when the lead
chiller assumes its role as a lead chiller then the lag chiller will
perform a RECOVERY START REQUEST (LL_MAINT
screen). The lead chiller will start up when the following conditions are met.
1. Lag chiller ramp loading must be complete.
2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
greater than CONTROL POINT plus 1/2 the CHILLED
WATER DEADBAND temperature.
3. Lag chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lag chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN) of the chilled water temperature is
less than 0.5 F (0.27 C) per minute.
5. The standby chiller is not running as a lag chiller.
6. The configured LAG START TIMER has elapsed. The
LAG START TIMER is started when ramp loading is
completed.
LOAD BALANCING — When the LOAD BALANCE OPTION (see LEADLAG screen) is enabled, the lead chiller sets
44
•
20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD — The ice build function
terminates under the following conditions:
1. Time Schedule — When the current time on the ice
build time schedule (OCCPC02S) is not set as an ice
build time period.
2. Entering Chilled Water Temperature — Compressor
operation terminates, based on temperature, if the ICE
BUILD TERMINATION parameter is set to 0 (TEMP),
the ENTERING CHILLED WATER temperature is less
than the ICE BUILD SETPOINT, and the ICE BUILDRECYCLE is set to DSABLE. If the ICE BUILD
RECYCLE OPTION is set to ENABLE, a recycle shutdown occurs and recycle start-up depends on the
LEAVING CHILLED WATER temperature being
greater than the WATER/BRINE CONTROL POINT
plus the RECYCLE RESTART DELTA T temperature
3. Remote Contacts/Ice Level Input — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 1 [CONTACTS] and the
remote contacts are open and the ICE BUILD RECYCLE is set to DSABLE (0). In this case, the contacts
provide ice level termination control. The contacts are
used to stop the ice build function when a time period
on the ice build schedule (OCCPC02S) is set for ice
build operation. The remote contacts can still be
opened and closed to start and stop the chiller when a
specific time period on the ice build schedule is not set
for ice build.
4. Entering Chilled Water Temperature and ICE BUILD
Contacts — Compressor operation terminates when
the ICE BUILD TERMINATION parameter is set to 2
(BOTH) and the conditions described above in items 2
and 3 for entering chilled water temperature and
remote contacts have occurred.
NOTE: It is not possible to override the CHILLER START/
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT
variables from CCN devices (with a priority 4 or greater) during the ice build period. However, a CCN device can override
these settings during 2-chiller lead/lag operation.
RETURN TO NON-ICE BUILD OPERATIONS — The ice
build function forces the chiller to start, even if all other schedules indicate that the chiller should stop. When the ice build
function terminates, the chiller returns to normal temperature
control and start/stop schedule operation. The CHILLER
START/STOP and CONTROL POINT return to normal operation. If the CHILLER START/STOP or CONTROL POINT has
been forced (with a device of less than 4 priority) before the ice
build function started, when the ice build function ends, the
previous forces (of less than 4 priority) are not automatically
restored.
ICE BUILD INITIATION — The ice build time schedule
(OCCPC02S) is the means for activating the ice build option.
The ice build option is enabled if:
• a day of the week and a time period on the ice build time
schedule are enabled. The SCHEDULE screen shows an
X in the day field and ON/OFF times are designated for
the day(s),
• and the ICE BUILD OPTION is enabled.
The following events take place (unless overridden by a
higher authority CCN device).
1. CHILLER START/STOP is forced to START.
2. The CONTROL POINT is forced to the ICE BUILD
SETPOINT.
3. Any force (Auto) is removed from the ACTIVE
DEMAND LIMIT.
NOTE: A parameter’s value can be forced, that is, the value
can be manually changed at the CVC by an operator, changed
from another CCN device, or changed by other algorithms in
the PIC II control system.
NOTE: Items 1-3 (shown above) do not occur if the chiller is
configured and operating as a lag or standby chiller for lead/lag
operation and is actively being controlled by a lead chiller. The
lead chiller communicates the ICE BUILD SET POINT, the
desired CHILLER START/STOP state, and the ACTIVE
DEMAND LIMIT to the lag or standby chiller as required for
ice build, if configured to do so.
START-UP/RECYCLE OPERATION — If the chiller is not
running when ice build activates, the PIC II checks the following conditions, based on the ICE BUILD TERMINATION value, to avoid starting the compressor unnecessarily:
• if ICE BUILD TERMINATION is set to the TEMP
option and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT;
• if ICE BUILD TERMINATION is set to the CONTACTS
option and the remote contacts are open;
• if the ICE BUILD TERMINATION is set to the BOTH
(temperature and contacts) option and the ENTERING
CHILLED WATER temperature is less than or equal to
the ICE BUILD SETPOINT and the remote contacts are
open.
The ICE BUILD RECYCLE on the OPTIONS screen determines whether or not the chiller will go into an ice build RECYCLE mode.
• If the ICE BUILD RECYCLE is set to DSABLE (disable), the PIC II reverts to normal temperature control
when the ice build function terminates.
• If the ICE BUILD RECYCLE is set to ENABLE, the PIC
II goes into an ICE BUILD RECYCLE mode and the
chilled water pump relay remains energized to keep the
chilled water flowing when the ice build function terminates. If the temperature of the ENTERING CHILLED
WATER increases above the ICE BUILD SETPOINT
plus the RECYCLE RESTART DELTA T value, the
compressor restarts and controls the chilled water/brine
temperature to the ICE BUILD SETPOINT.
TEMPERATURE CONTROL DURING ICE BUILD —
During ice build, the capacity control algorithm shall use the
CONTROL POINT minus 5 F (–2.8 C) for control of the
LEAVING CHILLED WATER temperature. See Table 3, example 9, the CAPACITY CONTROL parameter on the CAPACITY screen.) The ECW CONTROL OPTION and any
temperature reset option shall be ignored, if enabled, during ice
build. The AUTO DEMAND LIMIT INPUT shall also be
ignored if enabled during ice build.
• ECW CONTROL OPTION and any temperature reset
options (configured on TEMP_CTL screen).
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE
screen. From this screen, the operator can:
• enter the time schedule number (if changed) for
OCCPC03S, as defined in the NET_OPT screen
• attach the CVC to any CCN device, if the chiller has
been connected to a CCN network. This may include
other PIC- controlled chillers.
• upgrade software
Figure 27 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is always the CVC module address of the chiller on which it is mounted. Whenever the controller identification of the CVC changes, the change is reflected automatically in the BUS and ADDRESS columns for the
local device. See Fig. 21. Default address for local device is
BUS 0 ADDRESS 1.
45
TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered.
1. From the main MENU screen, press the SERVICE
softkey. The softkeys now correspond to the numerals
1, 2, 3, 4.
2. Press the four digits of the password, one at a time. An
asterisk (*) appears as each digit is entered.
Fig. 27 — Example of Attach to Network
Device Screen
NOTE: The initial factory-set password is 1-1-1-1.
If the password is incorrect, an error message is
displayed.
When the ATTACH TO NETWORK DEVICE screen is accessed, information can not be read from the CVC on any device until one of the devices listed on that screen is attached.
The CVC erases information about the module to which it was
attached to make room for information on another device.
Therefore, a CCN module must be attached when this screen is
entered.
To attach any CCN device, highlight it using the SELECT
softkey and press the ATTACH softkey. The message “UPLOADING TABLES, PLEASE WAIT” displays. The CVC
then uploads the highlighted device or module. If the module
address cannot be found, the message “COMMUNICATION
FAILURE” appears. The CVC then reverts back to the ATTACH TO DEVICE screen. Try another device or check the
address of the device that would not attach. The upload process
time for each CCN module is different. In general, the uploading process takes 1 to 2 minutes. Before leaving the ATTACH
TO NETWORK DEVICE screen, select the local device. Otherwise, the CVC will be unable to display information on the
local chiller.
If this occurs, return to Step 1 and try to access the
SERVICE screens again. If the password is correct, the
softkey labels change to:
NOTE: The SERVICE screen password can be changed by
entering the CVC CONFIGURATION screen under SERVICE
menu. The password is located at the bottom of the menu.
The CVC screen displays the following list of available
SERVICE screens:
• Alarm History
• Control Test
• Control Algorithm Status
• Equipment Configuration
• ISM (Starter) Config Data
• Equipment Service
• Time and Date
• Attach to Network Device
• Log Out of Device
• CVC Configuration
See Fig. 21 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
ATTACHING TO OTHER CCN MODULES — If the chiller CVC has been connected to a CCN Network or other PIC
controlled chillers through CCN wiring, the CVC can be used
to view or change parameters on the other controllers. Other
PIC II chillers can be viewed and set points changed (if the other unit is in CCN control), if desired, from this particular CVC
module.
If the module number is not valid, the “COMMUNICATION FAILURE” message will show and a new address number must be entered or the wiring checked. If the module is
communicating properly, the “UPLOAD IN PROGRESS”
message will flash and the new module can now be viewed.
Whenever there is a question regarding which module on
the CVC is currently being shown, check the device name descriptor on the upper left hand corner of the CVC screen. See
Fig. 27.
When the CCN device has been viewed, the ATTACH TO
NETWORK DEVICE table should be used to attach to the PIC
that is on the chiller. Move to the ATTACH TO NETWORK
DEVICE table (LOCAL should be highlighted) and press the
ATTACH softkey to upload the LOCAL device. The CVC
for the 23XL will be uploaded and default screen will display.
NOTE: To prevent unauthorized persons from accessing the
CVC service screens, the CVC automatically signs off and
password-protects itself if a key has not been pressed for
15 minutes. The sequence is as follows. Fifteen minutes after
the last key is pressed, the default screen displays, the CVC
screen light goes out (analogous to a screen saver), and the
CVC logs out of the password-protected SERVICE menu.
Other screen and menus, such as the STATUS screen can be
accessed without the password by pressing the appropriate
softkey.
TO LOG OUT OF NETWORK DEVICE — To access this
screen and log out of a network device, from the default CVC
screen, press the MENU and SERVICE softkeys. Enter the
password and, from the SERVICE menu, highlight LOG OUT
OF NETWORK DEVICE and press the SELECT softkey.
The CVC default screen will now be displayed.
NOTE: The CVC will not automatically reattach to the local
module on the chiller. Press the ATTACH softkey to attach to
the LOCAL device and view the chiller operation.
Service Operation — An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 21.
HOLIDAY SCHEDULING (Fig. 28) — The time schedules
may be configured for special operation during a holiday period. When modifying a time period, the “H” at the end of the
46
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 29)
Local Start-Up — Local start-up (or a manual start-up) is
days of the week field signifies that the period is applicable to a
holiday. (See Fig. 22.)
The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly. Access
the BRODEF screen from the EQUIPMENT CONFIGURATION table and select ENABLE to activate function. Note that
when the chiller is connected to a CCN Network, only one
chiller or CCN device can be configured as the broadcast device. The controller that is configured as the broadcaster is the
device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 21.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the
Service menu.
initiated by pressing the LOCAL menu softkey on the default
CVC screen. Local start-up can proceed when the chiller
schedule indicates that the current time and date have been
established as a run time and date, and after the internal
15-minute start-to-start and the 1-minute stop-to-start inhibit
timers have expired. These timers are represented in the START
INHIBIT TIMER and can be viewed on the MAINSTAT screen
and DEFAULT screen. The timer must expire before the chiller
will start. If the timers have not expired the RUN STATUS parameter on the MAINSTAT screen now reads TIMEOUT.
NOTE: The time schedule is said to be “occupied” if the
OCCUPIED ? parameter on the MAINSTAT screen is set to
YES. For more information on occupancy schedules, see the
sections on Time Schedule Operation (page 24), Occupancy
Schedule (page 37), and To Prevent Accidental Start-Up
(page 66), and Fig. 22.
If the OCCUPIED ? parameter on the MAINSTAT screen
is set to NO, the chiller can be forced to start as follows. From
the default CVC screen, press the MENU and STATUS
softkeys. Scroll to highlight MAINSTAT. Press the SELECT
softkey. Scroll to highlight CHILLER START/STOP. Press the
START softkey to override the schedule and start the chiller.
2. If not logged on, follow the instructions for ATTACH
TO NETWORK DEVICE or To Log Out. Once logged
on, press NEXT until Equipment Configuration is
highlighted.
3. Once Equipment Configuration is highlighted, press
SELECT to access.
4. Press NEXT until HOLIDAYS is highlighted. This is
the Holiday Definition table.
NOTE: The chiller will continue to run until this forced start is
released, regardless of the programmed schedule. To release
the forced start, highlight CHILLER START/STOP from the
MAINSTAT screen and press the RELEASE softkey. This
action returns the chiller to the start and stop times established
by the schedule.
The chiller may also be started by overriding the time
schedule. From the default screen, press the MENU and
SCHEDULE softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override
time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIPMENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE CONTACTS INPUT parameter on the MAINSTAT screen must be CLOSED. From the CVC default screen,
press the MENU and STATUS softkeys. Scroll to highlight MAINSTAT and press the SELECT softkey. Scroll
down the STATUS01 screen to highlight REMOTE CONTACTS INPUT and press the SELECT softkey. Then, press
the CLOSE softkey. To end the override, select REMOTE
CONTACTS INPUT and press the RELEASE softkey.
Once local start-up begins, the PIC II performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 4. The RUN STATUS parameter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. If the
tests are successful, the chilled water/brine pump relay energizes, and the MAINSTAT screen line now reads STARTUP.
Five seconds later, the condenser pump relay energizes.
Thirty seconds later the PIC II monitors the chilled water and
condenser water flow devices and waits until the WATER
FLOW VERIFY TIME (operator-configured, default 5 minutes)
expires to confirm flow. After flow is verified, the chilled water
temperature is compared to CONTROL POINT plus 1/2
CHILLED WATER DEADBAND. If the temperature is less
than or equal to this value, the PIC II turns off the condenser
pump relay and goes into a RECYCLE mode.
5. Press SELECT to enter the Data Table Select
screen.This screen lists 18 holiday tables.
6. Press NEXT to highlight the holiday table that is to
be viewed or changed. Each table is one holiday
period, starting on a specific date, and lasting up to 99
days.
7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start
month and day, and how many days the holiday period
will last.
8. Press NEXT or PREVIOUS to highlight the month,
day, or duration.
9. Press SELECT to modify the month, day, or duration.
10. Press INCREASE or DECREASE to change these
lected value.
11. Press ENTER to save the changes.
12. Press EXIT to return to the previous menu.
23XL
Fig. 28 — Example of Holiday Period Screen
47
shutdown, advances the starts in the12 hours counter by one,
and displays the applicable shutdown status on the CVC
display.
If the water/brine temperature is high enough, the start-up
sequence continues and checks the slide valve unload timer. If
the unload timer has expired, the PIC II then confirms the correct refrigerant type by comparing the cooler and condenser
refrigerant temperature to the leaving water temperature for
each vessel. If the refrigerant and leaving water temperatures
are within 15 F (8 C) for each respective vessel, compressor
start relay (1CR) energizes to start the compressor.
Compressor ontime and service ontime timers start, and the
compressor starts in 12 hours counter and the number of starts
over a 12-hour period counter advance by one.
Failure to verify any of the requirements up to this point will
result in the PIC II aborting the start and displaying the applicable pre-start mode of failure on the CVC default screen. A prestart failure does not advance the starts in 12 hours counter.
Any failure after the 1CR relay has energized results in a safety
Shutdown Sequence — Chiller shutdown begins if
any of the following occurs:
• the STOP button is pressed for at least one second (the
alarm light blinks once to confirm the stop command)
• a recycle condition is present (see Chilled Water Recycle
Mode section)
• the time schedule has gone into unoccupied mode
• the chiller protective limit has been reached and chiller
is in alarm
• the start/stop status is overridden to stop from the CCN
network or the CVC
When a stop signal occurs, the shutdown sequence first
stops the compressor by deactivating the start relay (1CR).
A status message of “SHUTDOWN IN PROGRESS,
COMPRESSOR DEENERGIZED” is displayed, and the compressor ontime and service ontime stop.
The slide valve unload timer is activated for 2 minutes to
move the slide valve to an open position. When the slide valve
unload timer expires, compressor start relay (1CR) is deenergized. The cooler water pump is shut down 30 seconds later.
The condenser pump is also shut down if the ENTERING
CONDENSER WATER temperature is greater than or equal to
115 F (46.1) and the CONDENSER REFRIG TEMP is greater
than the CONDENSER FREEZE POINT plus 5 F (3 C). The
stop-to-start timer now begins to count down. If the start-tostart timer value is still greater than the value of the start-tostop timer, then this time displays on the CVC.
Certain conditions that occur during shutdown can change
this sequence.
• If the AVERAGE LINE CURRENT is greater than 15%
after shutdown, or the starter contacts remain energized,
the chilled water pump remains energized and the alarm
is displayed.
• The condenser pump shuts down when the CONDENSER PRESSURE is less than the CONDENSER
PRESSURE OVERRIDE threshold minus 3.5 psi (24.1
kPa) and the CONDENSER REFRIG TEMP is less than
or equal to the ENTERING CONDENSER WATER
temperature plus 3º F (1.6º C).
• If the chiller shuts down due to low refrigerant temperature, the chilled water pump continues to run until
the LEAVING CHILLED WATER temperature is greater
than the CONTROL POINT temperature, plus 5º F
(3º C).
Automatic Soft Stop Amps Threshold —
The soft stop amps threshold feature closes the slide valve of
the compressor automatically if a non-recycle, non-alarm stop
signal occurs before the compressor motor is deenergized.
If the STOP button is pressed, the slide valve unloads to a
preset amperage percent, or the slide valve timer expires. The
compressor then shuts off.
If the chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.
To activate the soft stop amps threshold feature, scroll to the
bottom of OPTIONS screen on the CVC. Use the INCREASE
or DECREASE softkey to set the SOFTSTOP AMPS
THRESHOLD parameter to the percent of amps at which the
motor will shut down. The default setting is 100% amps (no
soft stop). The range is 40 to 100%.
A
— START INITIATED: Pre-start checks are made; evaporator pump
started
B — Condenser water pump started (5 seconds after A)
C — Water flows verified (30 seconds to 5 minutes maximum)
D — Chilled water temperature checked against control point; tower fan
control enabled; slide valve decrease timer checked to verify slide
valve position
E — Refrigerant type verified (up to 3 minutes after D).
F — Compressor motor starts; phase reversal conditions monitored; compressor ontime and service ontime start; 15-minute inhibit timer starts
(10 seconds after E)
G — Shutdown initiated: Compressor motor stops; compressor ontime and
service ontime stop; 3-minute inhibit timer starts on PSIO Software
Version 8 and 12 and 1-minute inhibit timer on PSIO Software Version
13 and higher; slide valve decrease activated for 1 minute
H — Evaporator pump deenergized (30 seconds after G); condenser
pump and tower fan control may continue to operate if condenser
pressure is high; evaporator pump may continue if in RECYCLE
mode
I
— Slide valve decrease timer expires (3 minutes after G)
O/A — Restart permitted (both inhibit timers expired) (minimum of 15 minutes after F; minimum of 1 minute after G)
When the soft stop amps threshold feature is being applied,
a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the CVC.
Fig. 29 — Control Sequence
48
BEFORE INITIAL START-UP
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.
Job Data Required
•
Chilled Water Recycle Mode — The chiller may
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This cycling is normal and is known as “recycle.” A recycle shutdown
is initiated when any of the following conditions are true:
• the chiller is in LCW control, the difference between the
LEAVING CHILLED WATER temperature and ENTERING CHILLED WATER temperature is less than the
RECYCLE SHUTDOWN DELTA T (found in the
SETUP1 table) and the LEAVING CHILLED WATER
temperature is below the CONTROL POINT, –5 F
(–15.0 C) the CONTROL POINT has not increased in the
last 5 minutes and ICE BUILD is not active.
• the ECW CONTROL OPTION is enabled, the difference
between the ENTERING CHILLED WATER temperature
and the LEAVING CHILLED WATER temperature is less
than the RECYCLE SHUTDOWN DELTA T (found in
the SETUP1 table), and the ENTERING CHILLED
WATER temperature is below the CONTROL POINT
–5 F (–15.0 C) and the CONTROL POINT has not
increased in the last 5 minutes.
• the LEAVING CHILLED WATER temperature is within
3º F (2º C) of the EVAP REFRIG TRIPPOINT.
When the chiller is in RECYCLE mode, the chilled water
pump relay remains energized so the chilled water temperature can be monitored for increasing load. The recycle control
uses RECYCLE RESTART DELTA T to check when the compressor should be restarted. This is an operator-configured
function which defaults to 5º F (3º C). This value can be
viewed or modified on the SETUP1 table. The compressor will
restart when the chiller is:
• in LCW CONTROL and the LEAVING CHILLED
WATER temperature is greater than the CONTROL
POINT plus the RECYCLE RESTART DELTA T.
• in ECW CONTROL and the ENTERING CHILLED
WATER temperature is greater than the CONTROL
POINT plus the RECYCLE RESTART DELTA T.
Once these conditions are met, the compressor initiates a
start-up with a normal start-up sequence.
An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can reduce chiller life; therefore, compressor recycling due to extremely low loads should be reduced.
To reduce compressor recycling, use the time schedule to
shut the chiller down during known low load operation period,
or increase the chiller load by running the fan systems. If the
hot gas bypass is installed, adjust the values to ensure that hot
gas is energized during light load conditions. Increase the
RECYCLE RESTART DELTA T on the SETUP1 table to
lengthen the time between restarts.
The chiller should not be operated below design minimum
load without a hot gas bypass installed.
•
•
•
•
•
list of applicable design temperatures and pressures
(product data submittal)
chiller certified prints
starting equipment details and wiring diagrams
diagrams and instructions for special controls or options
23XL Installation Instructions
pumpout unit instructions
Equipment Required
•
•
•
•
•
•
mechanic’s tools (refrigeration)
digital volt-ohmmeter (DVM)
clamp-on ammeter
electronic leak detector
absolute pressure manometer or wet-bulb vacuum indicator (Fig. 30)
500-v insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 v or less, or a
5000-v insulation tester for compressor motor rated
above 600 v
Using the Optional Storage Tank and Pumpout System — Refer to Chillers with Storage Tanks section, page 71 for pumpout system preparation, refrigerant
transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any packaging material from the control center, power panel, motor
cooling and oil reclaim solenoids, motor and bearing temperature sensor covers, and the factory-mounted starter.
Open Oil Circuit Valves — Check to ensure the oil filter isolation valves (Fig. 3 and 4) are open by removing the
valve cap and checking the valve stem.
Tighten All Gasketed Joints — Gaskets normally relax by the time the chiller arrives at the jobsite. Tighten all
gasketed joints to ensure a leak-tight chiller.
Check Chiller Tightness — Figure 31 outlines the
proper sequence and procedures for leak testing.
23XL chillers are shipped with a full refrigerant and oil
charge. Units may be ordered with the refrigerant shipped separately, and a 15 psig (103 kPa) nitrogen-holding charge in each
vessel. To determine if there are any leaks, the chiller should be
charged with a refrigerant tracer. Use an electronic leak detector to check all flanges and solder joints after the chiller is
pressurized. If any leaks are detected, follow the leak test
procedure.
If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and dam-age
during the transfer of refrigerant from vessel to vessel during
the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating
condition and the water circuits are full.
Refrigerant Tracer — Carrier recommends the use of an
environmentally acceptable refrigerant tracer for leak testing
with an electronic detector or halide torch.
Ultrasonic leak detectors can also be used if the chiller is
under pressure.
Safety Shutdown — A safety shutdown is identical to a
manual shutdown with the exception that, during a safety
shutdown, the CVC displays the reason for the shutdown, the
alarm light blinks continuously, and the spare alarm contacts
are energized.
After a safety shutdown, the RESET softkey must be
pressed to clear the alarm. If the alarm condition is still present,
the alarm light continues to blink. Once the alarm is cleared,
the operator must press the CCN or LOCAL softkeys to restart the chiller.
Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
49
Fig. 30 — Typical Wet-Bulb Type
Vacuum Indicator
3.
Leak Test Chiller — Due to regulations regarding refrigerant emissions and the difficulties associated with separating
contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 31 for an outline of the leak
test procedures. Refer to Fig. 24 and 25 during pumpout procedures. See the Pumpout and Refrigerant Transfer Procedures
Section on page 69. Refer to Tables 6A-6D for temperature/
pressure relationships for HCFC-22 and HFC-134a refrigerants. See Fig. 32-35.
1. If the pressure readings are normal for chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at equivalent saturated
pressure for the surrounding temperature.
4.
Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 68 psig (469 kPa) [35 psig
(241 kPa)]. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using
PUMPDOWN and TERMINATE PUMPDOWN/LOCKOUT mode on the PIC. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.
7.
5.
6.
c. Leak test chiller as outlined in Steps 3 - 7.
2. If the pressure readings are abnormal for chiller
condition:
a. Prepare to leak test chillers shipped with refrigerant. If chiller is shipped with refrigerant, proceed
to Step 2h.
50
b. Check for large leaks by connecting a nitrogen
bottle and raising the pressure to 30 psig
(207 kPa). Soap test all joints. If the test pressure
holds for 30 minutes, prepare the test for small
leaks (Steps 2g - h).
c. Plainly mark any leaks which are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest only those joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished
by following the dehydration procedure, outlined
in the Chiller Dehydration section, page 58.
h. Slowly raise the system pressure to normal operating pressures for the refrigerant used in the chiller.
Proceed with the test for small leaks (Steps 3 - 7).
Check the chiller carefully with an electronic leak
detector or halide torch.
Leak Determination — If an electronic leak detector
indicates a leak, use a soap bubble solution, if possible,
to confirm. Total all leak rates for the entire chiller.
Leakage at rates greater than 1 lb/year (0.45 kg/year)
for the entire chiller must be repaired. Note total
chiller leak rate on the start-up report.
If no leak is found during initial start-up procedures,
complete the transfer of refrigerant gas from the storage tank to the chiller. Retest for leaks.
If no leak is found after a retest
a. Transfer the refrigerant to the storage tank and
perform a standing vacuum test as outlined in the
Chiller Dehydration section, page 58.
b. If the chiller fails this test, check for large leaks
(Step 2b).
c. Dehydrate the chiller if it passes the standing
vacuum test. Follow the procedure in the
Chiller Dehydration section. Charge chiller with
refrigerant.
If a leak is found, pump the refrigerant back into the
storage tank, or if isolation valves are present, pump
into the vessel that is not leaking.
Transfer the refrigerant until chiller pressure is at least
equal to the pressure specified by the EPA under
40CFR Part 82.
Repair the leak and repeat the procedure, beginning
from Step 2h to ensure a leaktight repair. If chiller is
opened to the atmosphere for an extended period,
evacuate it before repeating leak test.
51
Fig. 31 — 23XL Leak Test Procedure
Fig. 32 — Typical Optional Pumpout System Piping Schematic with Storage Tank (TC Frame 1 and 2 Chillers)
52
Fig. 33 — Typical Optional Pumpout System Piping Schematic With Storage Tank (TD Frame 4 Chillers)
53
Fig. 34 — Typical Optional Pumpout System Piping Schematic Without Storage Tank
(TC Frame 1 and 2 Chillers)
54
Fig. 35 — Typical Optional Pumpout System Piping Schematic Without Storage Tank
(TD Frame 4 Chillers)
55
Table 6A — HCFC-22 Pressure — Temperature (F)
TEMPERATURE
(F)
–50
–48
–46
–44
–42
–40
–38
–36
–34
–32
–30
–28
–26
–24
–22
–20
–18
–16
–14
–12
–10
– 8
– 6
– 4
– 2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
PRESSURE (psi)
Absolute
Gage
11.67
6.154*
12.34
4.829*
13.00
3.445*
13.71
2.002*
14.45
0.498*
15.22
0.526
16.02
1.328
16.86
2.163
17.73
3.032
18.63
3.937
19.57
4.877
20.55
5.853
21.56
6.868
22.62
7.921
23.71
9.015
24.85
10.15
26.02
11.32
27.24
12.54
28.50
13.81
29.81
15.11
31.16
16.47
32.56
17.87
34.01
19.32
35.51
20.81
37.06
22.36
38.66
23.96
40.31
25.61
42.01
27.32
43.78
29.08
45.59
30.90
47.46
32.77
49.40
34.70
51.39
36.69
53.44
38.74
55.55
40.86
57.73
43.03
59.97
45.27
62.27
47.58
64.64
49.95
67.08
52.39
TEMPERATURE
(F)
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
PRESSURE (psi)
Absolute
Gage
69.59
54.90
72.17
57.47
74.82
60.12
77.54
62.84
80.34
65.64
83.21
68.51
86.15
71.46
89.18
74.48
92.28
77.58
95.46
80.77
98.73
84.03
102.07
87.38
105.50
90.81
109.02
94.32
112.62
97.93
116.31
101.62
120.09
105.39
123.96
109.26
127.92
113.22
131.97
117.28
136.12
121.43
140.37
125.67
144.71
130.01
149.15
134.45
153.69
138.99
158.33
143.63
163.07
148.37
167.92
153.22
172.87
158.17
177.93
163.23
183.09
168.40
188.37
173.67
193.76
179.06
199.26
184.56
204.87
190.18
210.60
195.91
216.45
201.76
222.42
207.72
228.50
213.81
234.71
220.02
TEMPERATURE
(F)
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
PRESSURE (psi)
Absolute
Gage
241.04
226.35
247.50
232.80
254.08
239.38
260.79
246.10
267.63
252.94
274.60
259.91
281.71
267.01
288.95
274.25
296.33
281.63
303.84
289.14
311.50
296.80
319.29
304.60
327.23
312.54
335.32
320.63
343.56
328.86
351.94
337.25
360.48
345.79
369.17
354.48
378.02
363.32
387.03
372.33
396.19
381.50
405.52
390.83
415.02
400.32
424.68
409.99
434.52
419.82
444.53
420.83
*Inches of mercury below one atmosphere.
Table 6B — HCFC-22 Pressure — Temperature (C)
TEMPERATURE
(C)
–18
–17
–16
–15
–14
–13
–12
–11
–10
– 9
– 8
– 7
– 6
– 5
– 4
– 3
– 2
– 1
0
1
2
3
4
5
6
7
8
9
10
PRESSURE (kPa)
Absolute
Gage
264
163
274
173
284
183
296
195
307
206
318
217
330
229
342
241
354
253
367
266
380
279
393
292
407
306
421
320
436
335
451
350
466
365
482
381
498
397
514
413
531
430
548
447
566
465
584
483
602
501
621
520
641
540
660
559
681
580
TEMPERATURE
(C)
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
PRESSURE (kPa)
Absolute
Gage
701
600
723
622
744
643
766
665
789
688
812
711
836
735
860
759
885
784
910
809
936
835
962
861
989
888
1020
919
1040
939
1070
969
1100
1000
1130
1030
1160
1060
1190
1090
1220
1120
1260
1160
1290
1190
1320
1220
1360
1260
1390
1290
1420
1320
1460
1360
1500
1400
1530
1430
56
TEMPERATURE
(C)
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
PRESSURE
Absolute
1570
1610
1650
1690
1730
1770
1810
1850
1900
1940
1980
2030
2080
2130
2170
2220
2270
2320
2370
2430
2480
2530
2590
2640
2700
2760
2820
2870
2930
3000
(kPa)
Gage
1470
1510
1550
1590
1630
1670
1710
1750
1800
1840
1890
1930
1980
2030
2070
2120
2170
2220
2270
2330
2380
2430
2490
2540
2600
2660
2720
2770
2830
2900
Table 6C — HFC-134a Pressure — Temperature (F)
TEMPERATURE, F
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
Table 6D — HFC-134a Pressure — Temperature (C)
PRESSURE (psig)
6.50
7.52
8.60
9.66
10.79
11.96
13.17
14.42
15.72
17.06
18.45
19.88
21.37
22.90
24.48
26.11
27.80
29.53
31.32
33.17
35.08
37.04
39.06
41.14
43.28
45.48
47.74
50.07
52.47
54.93
57.46
60.06
62.73
65.47
68.29
71.18
74.14
77.18
80.30
83.49
86.17
90.13
93.57
97.09
100.70
104.40
108.18
112.06
116.02
120.08
124.23
128.47
132.81
137.25
141.79
146.43
151.17
156.01
160.96
166.01
171.17
176.45
181.83
187.32
192.93
198.66
204.50
210.47
216.55
222.76
229.09
TEMPERATURE, C
-18.0
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
57
PRESSURE (kPa)
44.8
51.9
59.3
66.6
74.4
82.5
90.8
99.4
108.0
118.0
127.0
137.0
147.0
158.0
169.0
180.0
192.0
204.0
216.0
229.0
242.0
248.0
255.0
261.0
269.0
276.0
284.0
290.0
298.0
305.0
314.0
329.0
345.0
362.0
379.0
396.0
414.0
433.0
451.0
471.0
491.0
511.0
532.0
554.0
576.0
598.0
621.0
645.0
669.0
694.0
720.0
746.0
773.0
800.0
828.0
857.0
886.0
916.0
946.0
978.0
1010.0
1042.0
1076.0
1110.0
1145.0
1180.0
1217.0
1254.0
1292.0
1330.0
1370.0
1410.0
1451.0
1493.0
1536.0
1580.0
Chiller Dehydration — Dehydration is recommended if
the chiller has been open for a considerable period of time, if
the chiller is known to contain moisture, or if there has been a
complete loss of chiller holding charge or refrigerant pressure.
Do not start or megohm-test the compressor motor or oil
pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and
severe damage may result.
Fig. 36 — Dehydration Cold Trap
Inspect Water Piping — Refer to piping diagrams provided in the certified drawings and the piping instructions in
the 23XL Installation Instructions manual. Inspect the piping to
the cooler and condenser. Be sure that the flow directions are
correct and that all piping specifications have been met.
Piping systems must be properly vented with no stress on
waterbox nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser.
Inside-delta type starters must be disconnected by an isolation switch before placing the chiller under a vacuum
because one lead of each phase is live with respect to
ground even though there is not a complete circuit to run
the motor. To be safe, isolate any starter before evacuating
the chiller if you are not sure if there are live leads to the
hermetic motor.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 36) may substantially reduce the time required
to complete the dehydration. The higher the room temperature,
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low
ambient temperatures are involved, contact a qualified service
representative for the dehydration techniques required.
Perform dehydration as follows:
1. Connect a high capacity vacuum pump (5 cfm
[.002 m3/s] or larger is recommended) to the refrigerant charging valve (Fig. 2A and 2B). Tubing from the
pump to the chiller should be as short in length and as
large in diameter as possible to provide least resistance
to gas flow.
2. Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a
reading. Leave the valve open for 3 minutes to allow
the indicator vacuum to equalize with the chiller
vacuum.
3. If the entire chiller is to be dehydrated, open all isolation valves (if present).
4. With the chiller ambient temperature at 60 F (15.6 C)
or higher, operate the vacuum pump until the manometer reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)
(–100.61 kPa) or a vacuum indicator reads 35 F
(1.7 C). Operate the pump an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet
bulb vacuum indicator. At this temperature and pressure, isolated pockets of moisture can turn into ice.
The slow rate of evaporation (sublimation) of ice at
these low temperatures and pressures greatly increases
dehydration time.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete.
If the reading indicates vacuum loss, repeat Steps 4
and 5.
7. If the reading continues to change after several
attempts, perform a leak test up to the maximum
160 psig (1103 kPa) pressure. Locate and repair the
leak, and repeat dehydration.
Water must be within design limits, clean, and treated to
ensure proper chiller performance and to reduce the potential of tube damage due to corrosion, scaling, or erosion.
Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
Check Optional Pumpout Compressor Water
Piping — If the optional pumpout storage tank and/or pumpout system are installed, check to ensure the pumpout condenser water has been piped in. Check for field-supplied shutoff valves and controls as specified in the job data. Check for
refrigerant leaks on field-installed piping. See Fig. 32-35.
Check Relief Valves — Be sure the relief valves have
been piped to the outdoors in compliance with the latest edition
of ANSI/ASHRAE Standard 15 and applicable local safety
codes. Piping connections must allow for access to the valve
mechanism for periodic inspection and leak testing.
The 23XL relief valves are set to relieve at the 300 psig
(2069 kPa) chiller design pressure.
Inspect Wiring
Do not check the voltage supply without proper equipment
and precautions. Serious injury may result. Follow power
company recommendations.
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.
1. Examine the wiring for conformance to the job wiring
diagrams and all applicable electrical codes.
2. On low-voltage compressors (600 v or less) connect a
voltmeter across the power wires to the compressor
starter and measure the voltage. Compare this reading
to the voltage rating on the compressor and starter
nameplates.
58
supplied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication
bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the
positive pins of the system element on either side of it. The
negative pins must be wired to the negative pins. The signal
ground pins must be wired to the signal ground pins. See installation manual.
NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual
conductors must be insulated with PVC, PVC/nylon, vinyl,
Teflon, or polyethylene. An aluminum/polyester 100% foil
shield and an outer jacket of PVC, PVC/nylon, chrome vinyl,
or Teflon with a minimum operating temperature range of –4 F
to 140 F (–20 C to 60 C) is required. See table below for cables
that meet the requirements.
3. Compare the ampere rating on the starter nameplate to
rating on the compressor nameplate. The overload trip
amps must be 108% to 120%of the rated load amps.
4. The starter for a centrifugal compressor motor must
contain the components and terminals required for PIC
II refrigeration control. Check the certified drawings.
5. Check the voltage to the following components and
compare it to the nameplate values: pumpout compressor starter and power panel.
6. Ensure that fused disconnects or circuit breakers have
been supplied for the power panel and pumpout unit.
7. Ensure all electrical equipment and controls are properly grounded in accordance with job drawings, certified drawings, and all applicable electrical codes.
8. Ensure the customer’s contractor has verified proper
operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring
motors are properly lubricated and have proper electrical supply and proper rotation.
9. For field-installed starters only, test the chiller compressor motor and its power lead insulation resistance
with a 500-v insulation tester such as a megohmmeter.
(Use a 5000-v tester for motors rated over 600 v.) Factory-mounted starters do not require a megohm test.
a. Open the starter main disconnect switch and follow lockout/tagout rules.
MANUFACTURER
Alpha
American
Belden
Columbia
CABLE NO.
2413 or 5463
A22503
8772
02525
When connecting the CCN communication bus to a system
element, a color code system for the entire network is recommended to simplify installation and checkout. The following
color code is recommended:
+
CCN BUS CONDUCTOR
INSULATION COLOR
Red
CVC PLUG J1
PIN NO.
1
Ground
White
2
–
Black
3
SIGNAL TYPE
If the motor starter is a solid-state starter, the motor leads
must be disconnected from the starter before an insulation
test is performed. The voltage generated from the tester can
damage the starter solid-state components.
Check Starter
b. With the tester connected to the motor leads, take
10-second and 60-second megohm readings as
follows:
6-Lead Motor — Tie all 6 leads together and test
between the lead group and ground. Next tie the
leads in pairs: 1 and 4, 2 and 5, and 3 and 6. Test
between each pair while grounding the third pair.
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground.
c. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10- and
60-second readings must be at least 50 megohms.
If the readings on a field-installed starter are
unsatisfactory, repeat the test at the motor with the
power leads disconnected. Satisfactory readings in
this second test indicate the fault is in the power
leads.
NOTE: Unit-mounted starters do not have to be
megohm tested.
10. Tighten all wiring connections to the plugs on the ISM
and CCM modules.
11. Ensure that the voltage selector switch inside the
power panel is switched to the incoming voltage
rating.
On chillers with free-standing starters, inspect the
power panel to ensure that the contractor has fed the
wires into the bottom of the panel. Wiring into the top
of the panel can cause debris to fall into the contactors.
Clean and inspect the contactors if this has occurred.
BE AWARE that certain automatic start arrangements can
engage the starter. Open the disconnect ahead of the starter
in addition to shutting off the chiller or pump.
Use the instruction and service manual supplied by the
starter manufacturer to verify the starter has been installed correctly, to set up and calibrate the starter, and for complete troubleshooting information.
The main disconnect on the starter front panel may not
deenergize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
MECHANICAL STARTER
1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.
2. Check the contactor(s) to ensure they move freely.
Check the mechanical interlock between contactors to
ensure that 1S and 2M contactors cannot be closed at
the same time. Check all other electro-mechanical
devices, such as relays, for free movement. If the
devices do not move freely, contact the starter manufacturer for replacement components.
3. Some dashpot-type magnetic overload relays must be
filled with oil on the jobsite. If the starter is equipped
with devices of this type, remove the fluid cups from
these magnetic overload relays. Add the dashpot oil to
the cups according to the instructions supplied with the
starter. The oil is usually shipped in a small container
Carrier Comfort Network Interface — The Carrier
Comfort Network (CCN) communication bus wiring is
59
Software Configuration
attached to the starter frame near the relays. Use
only the dashpot oil supplied with the starter. Do not
substitute.
Solid-state overload relays do not have oil.
4. Reapply starter control power (not main chiller power)
to check the electrical functions.
Ensure the starter (with relay 1CR closed) goes
through a complete and proper start cycle.
Do not operate the chiller before the control configurations
have been checked and a Control Test has been satisfactorily completed. Protection by safety controls cannot
be assumed until all control configurations have been
confirmed.
BENSHAW, INC. REDISTART MICRO SOLID-STATE
STARTER
As the 23XL unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-12, provides a convenient list for configuration
values.
This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage.
Input the Design Set Points — Access the CVC set
point screen and view/modify the base demand limit set point,
and either the LCW set point or the ECW set point. The PIC II
can control a set point to either the leaving or entering chilled
water. This control method is set in the EQUIPMENT SERVICE (TEMP_CTL) table.
1. Ensure all wiring connections are properly terminated
to the starter.
2. Verify the ground wire to the starter is installed properly and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Ensure all of the relays are properly seated in their
sockets.
5. Verify the proper ac input voltage is brought into the
starter according to the certified drawings.
6. Apply power to the starter.
Input
the
Local
Occupied
Schedule
(OCCPC01S) — Access the schedule OCCPC01S screen
on the CVC and set up the occupied time schedule according to
the customer’s requirements. If no schedule is available, the default is factory set for 24 hours occupied, 7 days per week including holidays.
For more information about how to set up a time schedule,
see the Controls section, page 14.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
Oil Charge — The oil charge for the 23XL compressor
holds approximately 8 gal. (30 L) of oil.
The chiller is shipped with oil in the compressor. When the
sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom of
the lower sight glass (Fig. 2A and 2B). If oil is added, it must
meet Carrier’s specification for centrifugal compressor use as
described in the Oil Specification section. Charge the oil
through the oil charging valve located near the bottom of the
transmission housing (Fig. 2A and 2B). The oil must be
pumped from the oil container through the charging valve due
to higher refrigerant pressure. The pumping device must be
able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit
pressure. Oil should only be charged or removed when the
chiller is shut down.
Input Service Configurations — The following configurations require the CVC screen to be in the SERVICE portion of the menu.
• password
• input time and date
• CVC configuration
• service parameters
• equipment configuration
• automated control test
PASSWORD — When accessing the SERVICE tables, a password must be entered. All CVC are initially set for a password
of 1-1-1-1.
INPUT TIME AND DATE — Access the TIME AND DATE
table on the SERVICE menu. Input the present time of day,
date, and day of the week. The HOLIDAY TODAY parameter
should only be configured to YES if the present day is a
holiday.
NOTE: Because a schedule is integral to the chiller control
sequence, the chiller will not start until the time and date have
been set.
CHANGE CVC CONFIGURATION IF NECESSARY —
From the SERVICE table, access the CVC CONFIGURATION screen. From there, view or modify the CVC CCN address, change to English or SI units, and change the password.
If there is more than one chiller at the jobsite, change the CVC
address on each chiller so that each chiller has its own address.
Note and record the new address. Change the screen to SI units
as required, and change the password if desired.
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the compressor before energizing the controls. A circuit breaker in the starter energizes the oil heater and the control circuit. When first
powered, the CVC should display the default screen within a
short period of time.
The oil heater is energized by powering the control circuit.
This should be done several hours before start-up to minimize
oil-refrigerant migration. The oil heater is controlled by the
PIC II and is powered through a contactor in the power panel.
Starters contain a separate circuit breaker to power the heater
and the control circuit. This arrangement allows the heater to
energize when the main motor circuit breaker is off for service
work or extended shutdowns. The oil heater relay status (OIL
HEATER RELAY) can be viewed on the COMPRESS table on
the CVC. Oil sump temperature can be viewed on the CVC default screen.
SOFTWARE VERSION — The software part number is labeled on the backside of the CVC module. The software version also appears on the CVC configuration screen as the last
two digits of the software part number.
60
TO CHANGE THE PASSWORD — The password may be
changed from the CVC CONFIGURATION screen.
1. Press the MENU and SERVICE softkeys. Enter the
current password and highlight CVC CONFIGURATION. Press the SELECT softkey. Only the last 5
entries on the CVC CONFIG screen can be changed:
BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC,
and PASSWORD.
Configure SERVICE Tables — Access the SERVICE tables,
depicted on the next page, to modify or view the following to
jobsite parameters:
PARAMETER
Starter Type
Motor Rated Line
Voltage
Volt Transformer
Ratio
2. Use the ENTER softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
3. To change the digit, press the INCREASE or
DECREASE softkey. When the desired digit is seen,
press the ENTER softkey.
4. The next digit is highlighted. Change it, and the third
and fourth digits in the same way the first was
changed.
Motor Rated
Load Amps
Motor Locked
Rotor Trip
Starter LRA
Rating
Motor Current
CT Ratio
5. After the last digit is changed, the CVC goes to the
BUS parameter. Press the EXIT softkey to leave that
screen and return to the SERVICE menu.
Ground Fault
Current
Transformers
Ground Fault
CTRatio
Single Cycle
Dropout
Be sure to remember the password. Retain a copy
for future reference. Without the password, access to the
SERVICE menu will not be possible unless the
CVC_PSWD menu on the STATUS screen is accessed by
a Carrier representative.
Line Frequency
Line Frequency
Faulting
TO CHANGE THE CVC DISPLAY FROM ENGLISH TO
METRIC UNITS — By default, the CVC displays information in English units. To change to metric units, access the
CVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight CVC CONFIGURATION.
Press the SELECT softkey.
Stall/Hot Gas
Bypass Option
Minimum Load
Points (T1/P1)
Full (Maximum)
Load Points (T2/P2)
Chilled Medium
Evaporator
Refrigerant
Trippoint
Evaporator Flow
Delta P Cutout
Condenser Flow
Delta P Cutout
Diffuser Option
2. Use the ENTER softkey to scroll to US IMP/
METRIC.
3. Press the softkey that corresponds to the units desired
for display on the CVC (e.g., US or METRIC).
MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The CVC module address can be changed from the
CVC CONFIGURATION screen. Change this address for each
chiller if there is more than one chiller at the jobsite. Write the
new address on the CVC module for future reference.
INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six
service tables.
TABLE
ISM_CONF — Select 0 for full voltage,
1 for reduced voltage, or 2 for solid
state/variable frequency drive.
ISM_CONF — Per chiller identification
nameplate data.
ISM_CONF — Enter ratio (reduced to
a ratio to 1) of power transformer wired
to terminal J3 of ISM. If no transformer
is used enter 1.
ISM_CONF — Per chiller identification
nameplate data.
ISM_CONF — Per chiller identification
nameplate data. Enter locked rotor
delta amps (LR AMPS D-).
ISM_CONF — Enter value from nameplate in starter cabinet.
ISM_CONF — Enter ratio (reduced to
a ratio to 1) of current transformers
wired to terminal J4 of ISM.
ISM_CONF — Enter 0 if three ground
fault CTs are wired to terminal J5 of
ISM. Enter 1 if one ground fault CT is
used.
ISM_CONF — Enter ratio (reduced to
a ratio to 1) of ground fault CT.
ISM_CONF — ENABLE if motor
protection required from drop in line
voltage within one cycle.
ISM_CONF — Enter YES for 60 Hz or
NO for 50 Hz.
ISM_CONF — ENABLE if motor
protection required for drop in line
frequency.
OPTIONS — Default = 0 (Stall Limit)
Enter 1 if HGBP is installed.
OPTIONS — Per job data — See modify load points section.
OPTIONS — Per job data — See modify load points section.
SETUP1 — Enter water or brine.
SETUP1 — Usually 3° F (1.7° C)
below design refrigerant temperature.
SETUP1 — Enter 50% of design pressure drop to 0.5 psi (3.4 kPa).*
SETUP1 — Enter 50% of design pressure drop to 0.5 psi (3.4 kPa).*
SETUP2 — ENABLE for 5 size compressor only. See model number
nomenclature.
*With variable flow systems this point may be configured to the lower
end of the range.
NOTE: Other parameters on these screens are normally left at the
default settings; however, they may be changed by the operator as
required. The time and persistence settings on the ISM_CONF table
can be adjusted to increase or decrease the sensitivity to a fault
condition. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault
condition.
61
Minimum Load ∆P1:
71 – 38 = 33 psid (490 – 262 = 228 kPad)
Modify Minimum and Maximum Load Points (∆T1/P1;
∆ T2/P2) If NecessaryT — These pairs of chiller load points,
located on the OPTIONS screen, determine when to limit guide
valve travel or open the hot gas bypass valve when stall prevention is needed. These points should be set based on individual chiller operating conditions.
If after configuring a value for these points, stall prevention
is operating too soon or too late for conditions, these parameters should be changed by the operator.
An example of such a configuration is shown below.
Refrigerant: HCFC-134a
Estimated Minimum Load Conditions:
44 F (6.7 C) LCW
45.5 F (7.5 C) ECW
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
Estimated Maximum Load Conditions:
44 F (6.7 C) LCW
4 F (12.2 C) ECW
42 F (5.6 C) Suction Temperature
8 F (36.7 C) Condensing Temperature
Calculate Maximum Load — To calculate the maximum load
points, use the design load condition data. If the chiller full load
cooler temperature difference is more than 15 F (8.3 C), estimate the refrigerant suction and condensing temperatures at
this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
98 F (36.7 C) = 120 psig (1827 kPa) saturated
refrigerant pressure (HFC-134a)
Maximum Load ∆T2:
54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)
Maximum Load ∆P2:
120 – 37 = 83 psid (827 – 255 = 572 kPad)
To avoid unnecessary surge prevention, add about 10 psid
(70 kPad) to |P2 from these conditions:
∆T2 = 10º F (5.5º C)
∆P2 = 93 psid (642 kPad)
Calculate Minimum Load — To calculate the minimum load
conditions, estimate the temperature difference the cooler will
have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated
pressure and temperature for the particular refrigerant used.
Suction Temperature:
43 F (6.1 C) = 38 psig (262 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated
refrigerant pressure (HFC-134a)
Minimum Load ∆T1 (at 20% Load): 2 F (1.1 C)
Again, to avoid unnecessary surge prevention, add 20 psid
(140 kPad) at ∆P1 from these conditions:
∆T1 = 2 F (1.1 C)
∆P1 = 53 psid (368 kPad)
If surge prevention occurs too soon or too late:
LOAD
At low loads
(<50%)
At high loads
(>50%)
STALL
PREVENTION
OCCURS TOO
SOON
Increase P1 by
10 psid (70 kPad)
Increase P2 by
10 psid (70 kPad)
STALL
PREVENTION
OCCURS TOO
LATE
Decrease P1 by
10 psid (70 kPad)
Decrease P2 by
10 psid (70 kPad)
The differential pressure (∆P) and temperature (∆T) can be
monitored during chiller operation by viewing ACTIVE
DELTA P and ACTIVE DELTA T (HEAT_EX screen). Comparing STALL/HGBP DELTA T to active DELTA T will determine when the STALL PREVENTION function will occur.
The smaller the difference between the STALL/HGBP DELTA
T and the ACTIVE DELTA T values, the closer to stall
prevention.
MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to
select, view, or modify parameters. Carrier’s certified drawings
have the configuration values required for the jobsite. Modify
these values only if requested.
SERVICE Screen Modifications — Change the values on
these screens according to specific job data. See the certified
drawings for the correct values. Modifications can include:
• chilled water reset
• entering chilled water control (Enable/Disable)
• 4 to 20 mA demand limit
• auto restart option (Enable/Disable)
• remote contact option (Enable/Disable)
Owner-Modified CCN Tables — The following EQUIPMENT CONFIGURATION screens are described for reference only.
OCCDEFCS — The OCCDEFCS screen contains the Local
and CCN time schedules, which can be modified here or on the
SCHEDULE screen as described previously.
HOLIDAYS — From the HOLIDAYS screen, the days of the
year that holidays are in effect can be configured. See the holiday paragraphs in the Controls section for more details.
BRODEF — The BRODEF screen defines the start and end of
daylight savings time. Enter the dates for the start and end of
daylight savings if required for your location. BRODEF also
activates the Broadcast function which enables the holiday
periods that are defined on the CVC to take effect.
Other Tables — The CONSUME, NET_OPT, and RUNTIME screens contain parameters used with a CCN system.
See the applicable CCN manual for more information on these
screens. These tables can only be defined from a CCN Building Supervisor.
62
Perform a Control Test — Check the safety controls
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed function (Table 7).
The Automated Control Test checks all outputs and inputs
for function. It will also set the refrigerant type. The compressor must be in the OFF mode to operate the controls test. The
compressor can be put in OFF mode by pressing the STOP
push-button on the CVC. Each test asks the operator to confirm
the operation is occurring and whether or not to continue. If an
error occurs, the operator can try to address the problem as the
test is being done or note the problem and proceed to the next
test.
When the control test is finished or the EXIT softkey is
pressed, the test stops, and the CONTROL TEST menu displays. If a specific automated test procedure is not completed,
access the particular control test to test the function when
ready. The CONTROL TEST menu is described in the table
below.
CCM Pressure Thermistors
CCM Pressure Transducers
Pumps
Discrete Outputs
Slide Valve
Pumpdown/Lockout
Terminate Lockout
Refrigerant Type
HEAT_EX screen). To calibrate oil pressure or waterside flow device, view the particular reading
(CHILLED WATER DELTA P and CONDENSER
WATER DELTA P on the HEAT_EX screen). It should
read 0 psi (0 kPa). If the reading is not 0 psi (0 kPa),
but within ±5 psi (35 kPa), the value may be set to zero
by pressing the SELECT softkey while the appropriate transducer parameter is highlighted on the CVC
screen. Then press the ENTER softkey. The value will
now go to zero. No high end calibration is necessary
for flow devices.
If the transducer value is not within the calibration
range, the transducer returns to the original reading. If
the pressure is within the allowed range (noted above),
check the voltage ratio of the transducer. To obtain the
voltage ratio, divide the voltage (dc) input from the
transducer by the supply voltage signal (displayed in
CONTROL TEST menu in the CCM PRESSURE
TRANSDUCERS screen) or measure across the positive (+ red) and negative (– black) leads of the transducer. For example, the condenser transducer voltage
input is measured at CCM terminals J2-4 and J2-5.
The voltage ratio must be between 0.80 and 0.11 for
the software to allow calibration. Pressurize the transducer until the ratio is within range. Then attempt calibration again.
4. A high pressure point can also be calibrated between
25 and 250 psig (172.4 and 1723.7 kPa) by attaching a
regulated 250 psig (1724 kPa) pressure (usually from a
nitrogen cylinder). The high pressure point can be calibrated by accessing the appropriate transducer parameter on the HEAT_EX screen, highlighting the
parameter, pressing the SELECT softkey, and then
using the INCREASE or DECREASE softkeys to
adjust the value to the exact pressure on the refrigerant
gage. Press the ENTER softkey to finish the calibration. Pressures at high altitude locations must be compensated for, so the chiller temperature/pressure
relationship is correct.
Check of all thermistors.
Check of all transducers.
Checks operation of pump
outputs; pumps are activated.
Also tests associated inputs
such as flow or pressure.
Activation of all on/off outputs
individually.
Check of the slide valve
operation.
Pumpdown prevents the low
refrigerant alarm during evacuation so refrigerant can be
removed form the unit. Also
locks the compressor off and
starts the water pumps.
To charge refrigerant and
enable the chiller to run after
pumpdown lockout.
Sets type of refrigerant used:
HFC-22 or HFC-134a.
NOTE: During any of the tests, an out-of-range reading will have an
asterisk (*) next to the reading and a message will be displayed.
COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION —
Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the
HEAT_EX screen on the CVC. The transducer can be checked
and calibrated at 2 pressure points. These calibration points are
0 psig (0 kPa) and between 25 and 250 psig (173 and
1724 kPa). To calibrate these transducers:
1. Shut down the compressor, cooler, and condenser
pumps.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its
Schrader fitting for cooler or condenser transducer calibration. For oil pressure or flow device calibration
keep transducer in place.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the
transducer from the vessel.
3. Access the HEAT_EX screen and view the particular
transducer reading (the EVAPORATOR PRESSURE or
CONDENSER PRESSURE parameter on the
The PIC II does not allow calibration if the transducer is too
far out of calibration. In this case, a new transducer must be installed and re-calibrated.
Check Optional Pumpout System Controls
and Compressor — Controls include an on/off switch, a
3-amp fuse, the compressor overloads, an internal thermostat, a
compressor contactor, and a refrigerant high pressure cutout.
The high pressure cutout is factory set to open at 161 psig
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the watercooled condenser has been connected. Loosen the compressor
holddown bolts to allow free spring travel. Open the compressor suction and discharge the service valves. Ensure oil is visible in the compressor sight glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 69 and
76, for details on the transfer of refrigerant, oil specifications,
etc.
High Altitude Locations — Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the
pressure transducers if the chiller has been moved to a high
altitude location. See the calibration procedure in the Troubleshooting Guide section.
63
Table 7 — Control Test Menu Functions
TESTS TO BE
PERFORMED
1. CCM Thermistors
2. CCM Pressure
Transducers
3. Pumps
4. Discrete Outputs
5. Slide Valve
6. Pumpdown
Lockout
7. Terminate Lockout
8. Refrigerant Type
CHILLER EQUALIZATION WITHOUT A PUMPOUT
UNIT
DEVICES TESTED
Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Remote Reset Sensor
Comp Discharge Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Space Temperature 2
Evaporator Pressure
Condenser Pressure
Spare Pressure Delta P
Condenser Water Delta P
Transducer Voltage Ref
Chilled Water — Confirm Delta P
Condenser Water — Confirm
Delta P
Oil Heater Relay
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
Alarm Relay
Shunt Trip Relay
Load (close); Unload (open)
When using pumpdown/lockout,observe
freeze up precautions when removing
charge:
Instructs operator which valves to close
and when.
Starts chilled water and
condenser water pumps and
confirms flows.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
Locks out compressor.
Starts pumps and monitors flows.
Instructs operator which valves to open
and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Terminates compressor lockout.
Sets the refrigerant type used: HFC-22
or HFC-134a.
When equalizing refrigerant pressure on the 23XL chiller
after service work or during the initial chiller start-up, do
not use the discharge isolation valve to equalize. Either the
motor cooling isolation valve or the charging hose (connected between the pumpout valves on top of the cooler
and condenser) should be used as the equalization valve.
To equalize the pressure differential on a refrigerant isolated
23XL chiller, use the terminate lockout function of the CONTROL TEST on the SERVICE menu. This helps to turn on
pumps and advises the operator on proper procedures.
The following steps describe how to equalize refrigerant
pressure in an isolated 23XL chiller without a pumpout unit.
1. Access terminate lockout function on the CONTROL
TEST screen.
2.
IMPORTANT: Turn on the chilled water and
condenser water pumps to prevent freezing.
3. Slowly open the refrigerant cooling isolation valve.
The chiller cooler and condenser pressures will gradually equalize. This process takes approximately
15 minutes.
4. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas
isolation valve may now be opened. Refer to Fig. 3235, for the location of the valves.
Whenever turning the discharge isolation valve, be sure to
reattach the valve locking device. This prevents the valve
from opening or closing during service work or during
chiller operation.
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
The following steps describe how to equalize refrigerant pressure on an isolated 23XL chiller using the pumpout unit.
1. Access the terminate lockout function on the CONTROL TEST screen.
2.
Charge Refrigerant into Chiller
IMPORTANT: Turn on the chilled water and
condenser water pumps to prevent possible freezing.
3. Open valve 4 on the pumpout unit and open valves 1a
and 1b on the chiller cooler and condenser, Fig. 32-35.
Slowly open valve 2 on the pumpout unit to equalize
the pressure. This process takes approximately
15 minutes.
4. Once the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas
bypass isolation valve, and the refrigerant isolation
valve can be opened. Close valves 1a and 1b, and all
pumpout unit valves.
The transfer, addition, or removal of refrigerant in spring
isolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups.
Whenever turning the discharge isolation valve, be sure to
reattach the valve locking device. This prevents the valve
from opening or closing during service work or during
chiller operation.
The standard 23XL chiller is shipped with the refrigerant already charged in the vessels. However, the 23XL may be ordered with a nitrogen holding charge of 15 psig (103 kPa).
Evacuate the nitrogen from the entire chiller, and charge the
chiller from refrigerant cylinders.
64
The full refrigerant charge on the 23XL will vary with chiller components and design conditions, as indicated on the job
data specifications. An approximate charge may be determined
by adding the condenser charge to the cooler charge as listed in
Table 8.
Do not permit water or brine that is warmer than 110 F
(43 C) to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief valves and
result in the loss of refrigerant charge.
7. Access the CONTROL TEST screen. Scroll down on
the TERMINATE LOCKOUT option. Press the
SELECT (to enable the chiller to start) and answer
YES to restart unit to operating mode. The chiller is
locked out at the factory in order to prevent accidental
start-up.
Always operate the condenser and chilled water pumps
whenever charging, transferring, or removing refrigerant
from the chiller.
Use the CONTROL TEST terminate lockout function to
monitor conditions and start the pumps.
If the chiller has been shipped with a holding charge, the
refrigerant is added through the refrigerant charging valve
(Fig. 32-35, valves 7a and 7b) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the
chiller vessels. Charge the refrigerant as a gas until the system
pressure exceeds 68 psig (469 kPa) for R-22, and 35 psig
(141 kPa) for HFC-134a. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the
recommended refrigerant charge has been added.
TRIMMING REFRIGERANT CHARGE — T h e 2 3 X L
chiller is shipped with the correct charge for the design duty of
the chiller. Trimming the charge can best be accomplished
when the design load is available. To trim the charge, check the
temperature difference between the leaving chilled water temperature and cooler refrigerant temperature at full load design
conditions. If necessary, add or remove refrigerant to bring
the temperature difference to design conditions or minimum
differential.
Dry Run to Test Start-Up Sequence
1. Disengage the main motor disconnect on the starter
front panel. This should only disconnect the motor
power. Power to the controls, oil pump, and starter
control circuit should still be energized.
2. Observe the default screen on the CVC: the Status
message in the upper left-hand corner reads, “Manually Stopped.” Press the CCN or LOCAL softkey to
start. If the chiller controls do not go into a start mode,
go to the Schedule screen and override the schedule or
change the occupied time. Press the LOCAL softkey
to begin the start-up sequences.
3. Verify the chilled water and condenser water pumps
have energized.
4. Verify the oil pump has started and is pressurizing the
lubrication system. After the oil pump has run about
11 seconds, the starter energizes and goes through its
start-up sequence.
5. Check the main contactor for proper operation.
6. The PIC II eventually shows an alarm for motor amps
not sensed. Reset this alarm and continue with the initial start-up.
INITIAL START-UP
Preparation — Before starting the chiller, verify:
1. Power is on to the main starter, oil pump relay, tower
fan starter, oil heater relay, and the chiller control
panel.
2. Cooling tower water is at proper level and at-or-below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant
and oil valves are in their proper operating positions.
4. Oil is at the proper level in the reservoir sight glasses.
5. Oil reservoir temperature is above 140 F (60 C) or
refrigerant temperature plus 50º F (28º C).
6. Valves in the evaporator and condenser water circuits
are open.
NOTE: If the pumps are not automatic, ensure water is circulating properly.
Check Oil Pressure and Compressor Stop
1. Two minutes after start-up, note the oil pressure reading on the CVC default screen. The value is equal to
the difference between the oil and evaporator pressure
transducer readings. The minimum oil pressure is 7 to
20 psi (48 to 137 kPa). The oil and evaporator pressure
transducer readings can be observed on the COMPRESS and HEAT-EX table. A normal full load
reading is approximately 120 psi (827 kPa) [78 psi
(538 kPa)].
2. Press the STOP softkey and listen for any unusual
sounds from the compressor as it coasts to a stop.
Table 8 — Refrigerant Charges
REFRIGERANT
COOLER SIZE
10,11
20,21
40
41
42
43
ECONOMIZER
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
HCFC-22
lb
600
650
700
750
900
1000
1000
1100
1100
1200
1200
1300
HFC-134a
kg
272
295
318
340
408
454
454
499
499
544
544
590
*Not available or retrofitable when using HFC-134a.
65
lb
*
*
*
*
800
850
850
900
900
950
950
1000
kg
*
*
*
*
363
386
386
408
408
431
431
454
To Prevent Accidental Start-Up — A chiller STOP
override setting may be entered to prevent accidental start-up
during service or whenever necessary. Access the MAINSTAT
screen and using the NEXT or PREVIOUS softkeys, highlight the CHILLER START/STOP parameter. Override the current START value by pressing the SELECT softkey. Press the
STOP softkey followed by the ENTER softkey. The word
SUPVSR! displays on the CVC indicating the override is in
place.
CHECK OPERATOR KNOWLEDGE — Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP OPERATION, AND MAINTENANCE MANUAL.
OPERATING INSTRUCTIONS
Operator Duties
1. Become familiar with the chiller and related equipment before operating the chiller.
2. Prepare the system for start-up, start and stop the
chiller, and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document
any abnormal readings.
4. Inspect the equipment, make routine adjustments, and
perform a Control Test. Maintain the proper oil and
refrigerant levels.
5. Protect the system from damage during shutdown
periods.
6. Maintain the set point, time schedules, and other PIC
functions.
To restart the chiller the STOP override setting must be removed. Access the MAINSTAT screen and using NEXT or
PREVIOUS softkeys highlight CHILLER START/STOP. The
3 softkeys that appear represent 3 choices:
•
•
•
START — forces the chiller ON
STOP — forces the chiller OFF
RELEASE — puts the chiller under remote or schedule
control.
To return the chiller to normal control, press the
RELEASE softkey followed by the ENTER softkey. For
more information, see Local Start-Up, page 47.
Prepare the Chiller for Start-Up — Follow the
steps described in the Initial Start-Up section, page 65.
The default CVC screen message line indicates which command is in effect.
To Start the Chiller
Check Chiller Operating Condition — Check
to
be sure that chiller temperatures, pressures, water flows, and
oil and refrigerant levels indicate the system is functioning
properly.
1. Start the water pumps, if they are not automatic.
2. On the CVC default screen, press the LOCAL or
CCN softkey to start the system. If the chiller is in
the OCCUPIED mode and the start timers have
expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/Recycle
Sequence section, page 47.
Instruct the Customer Operator — Ensure the operator(s) understand all operating and maintenance procedures.
Point out the various chiller parts and explain their function as
part of the complete system.
COOLER-CONDENSER — Float chamber, relief valves, refrigerant charging valve, temperature sensor locations, pressure
transducer locations, Schrader fittings, waterboxes and tubes,
and vents and drains.
OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system,
refrigerant charging and pumpdown procedure, and relief
devices.
MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system,
temperature and pressure sensors, oil sight glasses, integral oil
pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.
MOTOR COMPRESSOR LUBRICATION SYSTEM —
Oil pump, cooler filter, oil heater, oil charge and specification,
operating and shutdown oil level, temperature and pressure,
and oil charging connections.
CONTROL SYSTEM — CCN and LOCAL start, reset,
menu, softkey functions, CVC operation, occupancy schedule,
set points, safety controls, and auxiliary and optional controls.
AUXILIARY EQUIPMENT — Starters and disconnects,
separate electrical sources, pumps, and cooling tower.
DESCRIBE CHILLER CYCLES — Refrigerant, motor
cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free chiller.
SAFETY DEVICES AND PROCEDURES — Electrical
disconnects, relief device inspection, and handling refrigerant.
Check the Running System — After the compressor starts, the operator should monitor the CVC display and observe the parameters for normal operating conditions:
1. The oil sump temperature should be 20 to 40 F (11 to
20 C) above the condenser refrigerant temperature. At
start-up, the oil sump temperature will rapidly
decrease. It will then slowly rise to the compressor discharge temperature. After start-up, the minimum oil
sump temperature should be 20 F (11 C) above the
condenser refrigerant temperature. The oil sump temperature is dependent upon the compressor discharge
refrigerant temperature.
2. When the compressor is running, the oil sump should
be at least 3/4 full. The liquid level should be visible in
the separator sight glass.
3. The oil pressure displayed on the CVC default screen
is equal to the difference between the oil pressure and
evaporator pressure transducer readings. Typically the
reading will be 4 to 20 psi (28 to 138 kPa) [1.4 to 7 psi
(9.7 to 48.3 kPa)] at initial start-up until oil pressure
ramp up is complete. The full load reading is approximately 120 psi (821 kPa) [78 psi (538 kPa)].
4. The moisture indicator (dry-eye) sight glass on the
refrigerant motor cooling line should indicate refrigerant flow and a dry condition.
5. The condenser pressure and temperature varies with
the chiller design conditions. Typically the pressure
will range between 100 and 210 psig (690 to
1450 kPa) [60 to 135 psig (329 to 780 kPa)] with a
corresponding temperature range of 60 to 105 F (15 to
41 C). The condenser entering water temperature may
be controlled below the specified design entering
66
is a good time to brush the tubes and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary.
Check the cooler pressure on the CVC default screen and
compare it to the original holding charge that was left in the
chiller. If (after adjusting for ambient temperature changes) any
loss in pressure is indicated, check for refrigerant leaks. See
Check Chiller Tightness section, page 49.
Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures section, this page. Observe
freeze-up precautions.
Carefully make all regular preliminary and running system
checks. Perform a Control Test before start-up. If the oil level
appears abnormally high, the oil may have absorbed refrigerant. TD frame 4 chillers are able to start with an abnormally
high oil level. Ensure that the oil temperature is above refrigerant temperature plus 35º F (19º C) (TC frame 1 and 2 chillers
only).
NOTE: TD frame 4 chillers do not have an oil heater.
water temperature to save on compressor kilowatt
requirements but, not be below 55 F (12.8 C).
6. Cooler pressure and temperature also will vary with
the design conditions. Typical pressure range will be
between 60 and 80 psig (410 and 550 kPa) [30 to
40 psig (204 to 260 kPa)] with temperature ranging
between 34 and 45 F (1 and 8 C).
7. The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even
though the building load is small. The active electrical
demand setting can be overridden to limit the compressor IkW, or the pulldown rate can be decreased to
avoid a high demand charge for the short period of
high demand operation. Pulldown rate can be based on
load rate or temperature rate. It is accessed on the
Equipment SERVICE screen, RAMP_DEM table
(Table 3, Example 20).
To Stop the Chiller
1. The occupancy schedule starts and stops the chiller
automatically once the time schedule is configured.
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been
pressed. The compressor will then follow the normal
shutdown sequence as described in the Controls section. The chiller will not restart until the CCN or
LOCAL softkey is pressed. The chiller is now in the
OFF control mode.
Cold Weather Operation — When the entering condenser water drops very low (55 F [13 C] minimum), the operator should automatically cycle the cooling tower fans off to
keep the temperature up. Piping may also be arranged to bypass the cooling tower. The PIC II controls have a low limit
tower fan output that can be used to assist in this control (terminal 11 and 12 on ISM).
Slide Valve Operation — Manual operation of the
slide valve to check control operation, or to control the valve in
an emergency operation, is possible by overriding the manual
slide valve count. Access the Status COMPRESS table on the
CVC and highlight MANUAL SLIDE VALVE. To control slide
valve movement, enter a desired count value. The MANUAL
SLIDE VALVE LOAD/UNLOAD has an allowable input range
of plus or minus 10 to provide up to 10 seconds of slide valve
movement in the selected direction. If the counts are positive
then the slide valve position will increase to load the compressor and vice versa. To release the valve to PIC II control press
the RELEASE softkey.
If the chiller fails to stop, in addition to action that the
PIC will initiate, the operator should open the slide
valve to reduce chiller load by overriding the slide
valve count to –20. Then, the operator should open the
main disconnect.
IMPORTANT: Do not attempt to stop the chiller by
opening an isolating knife switch. High intensity arcing
may occur.
Do not restart the chiller until the problem is diagnosed and
corrected.
NOTE: The valve can be increased with manual control to
override the pulldown rate during start-up. However, motor
current above the electrical demand setting, capacity overrides,
and chilled water below control point will override the manual
count and decrease the slide valve position. For descriptions of
capacity overrides and set points, see the Controls section.
Entering a 0 count value will cause the slide valve to maintain a HOLD state. In this condition, the slide valve will respond to maintain the chilled water (∆T) temperature when the
override occurs.
After Limited Shutdown — No special preparations
should be necessary. Follow the regular preliminary checks and
starting procedures.
Preparation for Extended Shutdown — The
refrigerant should be transferred into the pumpout storage tank
(if supplied; see Pumpout and Refrigerant Transfer Procedures)
to reduce chiller pressure and the possibility of leaks. Maintain
a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or
nitrogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller
area, drain the chilled water, condenser water, and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open.
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.
Refrigeration Log — A refrigeration log, such as the
one shown in Fig. 37, provides a convenient checklist for routine inspection and maintenance, and provides a continuous
record of chiller performance. It is an aid in scheduling routine
maintenance and in diagnosing chiller problems.
Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to that shown. Automatic recording of PIC II data is possible through the use of CCN devices
such as the Data Collection module and a Building Supervisor.
Contact your Carrier representative for more information.
After Extended Shutdown — Ensure the water system drains are closed. It may be advisable to flush the water
circuits to remove any soft rust which may have formed. This
67
68
Press. Temp
Refrigerant
In Out GPM
COOLER
Water
Pressure
SERIAL NO.
REFRIGERANT TYPE
CONDENSER
COMPRESSOR
Refrigerant
Water
Oil
Motor
ROTOR
FLA
Temp
Pressure
Temp INLET DISCHARGE
Filter
TEMP
Press. Temp
Press. Diff. Temp Level Voltage
In Out
In Out GPM In Out TEMP
Amperage
Press
MODEL NO.
Fig. 37 — Refrigeration Log: Carrier 23XL Hermetic Screw Refrigeration
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, operating hours, start counts, and air exhausted. Include amounts.
TIME
DATE
Plant
OPERATOR REMARKS
INITIALS
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
2. To determine pumpout storage tank pressure, a 30 in.
–0-400 psi (–101-0-2769 kPa) gage is attached to the
storage tank.
3. Refer to Fig. 32-35, and 39 for valve locations andnumbers.
Preparation — The 23XL may come equipped with an
optional pumpout storage tank, pumpout system, or pumpout
compressor. The refrigerant can be pumped for service work to
either the chiller compressor evaporator vessel or chiller condenser vessel by using the optional pumpout system. If a
pumpout storage tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe how
to transfer refrigerant from vessel to vessel and perform chiller
evacuations.
Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
Always run the chiller cooler and condenser water pumps
and always charge or transfer refrigerant as a gas when the
chiller pressure is less than 30 psig (207 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
During transfer of refrigerant into and out of the optional
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank or personal injury.
C
FU
HP
OL
T’STAT
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
—
—
—
—
—
LEGEND
Contactor
Fuse, 3 Amps
High-Pressure Cutout
Compressor Overload
Internal Thermostat
Compressor Terminal
Contactor Terminal
Operating the Optional Pumpout Unit
Overload Terminal
Pumpout Unit Terminal
1. Be sure that the suction and the discharge service
valves on the optional pumpout compressor are open
(backseated) during operation. Rotate the valve stem
fully counterclockwise to open. Frontseating the valve
closes the refrigerant line and opens the gage port to
compressor pressure.
2. Ensure that the compressor holddown bolts have been
loosened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the pumpout unit compressor
sight glass under all operating conditions and during
shutdown. If oil is low, add oil as described under
Optional Pumpout System Maintenance section,
page 76. The pump-out unit control wiring schematic
is detailed in Fig. 38.
TO READ REFRIGERANT PRESSURES during pumpout or
leak testing:
1. The CVC display on the chiller control panel is suitable for determining refrigerant-side pressures and low
(soft) vacuum. To assure the desired range and accuracy when measuring evacuation and dehydration, use
a quality vacuum indicator or manometer. This can be
placed on the Schrader connections on each vessel
(Fig. 11 and 12) by removing the pressure transducer.
*Bimetal thermal protector imbedded in motor winding.
Fig. 38 — 23XL Pumpout Unit Wiring Schematic
OIL RETURN
LINE
CONNECTION
CONDENSER
WATER
CONNECTIONS
REFRIGERANT
INLET VALVE
Fig. 39 — Optional Pumpout Unit
69
Chillers with Isolation Valves
e. Turn off the pumpout compressor.
2. Evacuate the refrigerant gas from the chiller condenser
vessel.
a. Access the PUMPDOWN LOCKOUT function
accessed from the CVC CONTROL TEST table to
turn on the chiller water pumps. Turn the chiller
water pumps on manually if they are not controlled by the PIC II.
b. Close pumpout unit valves 3 and 4; open valves 2
and 5.
TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL — For chillers with isolation valves, refrigerant can be stored in one chiller vessel or the other without
the need for an external storage tank.
1. Push refrigerant into the chiller condenser.
a. Valve positions:
VALVE
1a 1b 2
CONDITION
3 4
C C
5
8 11 12 13 14
C
C C C
b. Using the PIC II controls, turn off the chiller water
pumps and pumpout condenser water. If the chiller
water pumps are not controlled through the PIC II,
turn them off manually.
c. Turn on the pumpout compressor to push the liquid refrigerant out of the chiller cooler vessel.
d. When all liquid refrigerant has been pushed into
the chiller condenser vessel, close chiller isolation
valve 11.
e. Access the PUMPDOWN LOCKOUT screen on
the PIC II CONTROL TEST table to turn on the
chiller water pumps. If the chiller water pumps are
not controlled by the PIC II, turn them on manually.
f. Turn off the pumpout compressor.
2. Evacuate the refrigerant gas from chiller cooler vessel.
a. Close pumpout compressor valves 2 and 5, and
open valves 3 and 4.
VALVE
1a 1b 2
C
CONDITION
3
4
VALVE
1a 1b 2
CONDITION
h. Turn off the pumpout condenser water.
i. Proceed to the PUMPDOWN LOCKOUT test
from the CVC CONTROL TEST table to turn off
the chiller water pumps and lock out the chiller
compressor. Turn off the chiller water pumps manually if they are not controlled by the PIC II.
RETURN CHILLER TO NORMAL OPERATING
CONDITIONS
1. Ensure vessel that was opened has been evacuated.
2. Access the TERMINATE LOCKOUT function CVC
from the CONTROL TEST table to view vessel pressures and turn on chiller water pumps. If the chiller
water pumps are not controlled by the PIC II, turn
them on manually.
3. Open valves 1a, 1b, and 3.
5 8 11 12 13 14
C C C C C C
VALVE
CONDITION
1a 1b 2
C
3
4
C
5
C
8 11 12 13 14
C C C C C
4. Slowly open valve 5, gradually increasing pressure in
the evacuated vessel to 35 psig (141 kPa). Feed refrigerant slowly to prevent tube freeze up.
5. Leak test to ensure vessel integrity.
6. Open valve 5 fully.
g. Turn off the pumpout condenser water.
h. Proceed to the PUMPDOWN/LOCKOUT function accessed from the CONTROL TEST table to
turn off the chiller water pumps and lock out the
chiller compressor. Turn off the chiller water
pumps manually if they are not controlled by the
PIC II.
TRANSFER ALL REFRIGERANT TO CHILLER
COOLER VESSEL
1. Push the refrigerant into the chiller cooler vessel.
a. Valve positions:
4
8 11 12 13 14
C C C C C
VALVE
1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C C C C C
VALVE
1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C C C C C
3
5
c. Turn on the pumpout condenser water.
d. Run the pumpout compressor until the chiller condenser pressure reaches 18 in. Hg vac (40 kPa
abs.). Monitor pressure at the CVC and at refrigerant gages.
e. Close valve 1b.
f. Turn off the pumpout compressor.
g. Close valves 1a, 2, and 5.
b. Turn on the pumpout condenser water.
c. Run the pumpout compressor until the chiller
cooler vessel pressure reaches 18 in. Hg vac
(40 kPa abs.). Monitor pressures on the CVC and
on refrigerant gages.
d. Close valve 1a.
e. Turn off the pumpout compressor.
f. Close valves 1b, 3, and 4.
VALVE
1a 1b 2
C
CONDITION
3 4
C C
VALVE
CONDITION
1a 1b 2
C
3
4
C
5
8 11 12 13 14
C C C C C
7. Open valve 11 to equalize the liquid refrigerant level
between the vessels.
8. Close valves 1a, 1b, 3, and 5.
9. Open isolation valves 12, 13, and 14 (if present).
5 8 11 12 13 14
C C
C C C
VALVE
CONDITION
b. Turn off the chiller water pumps (either through
the PIC II controls or manually, if necessary) and
the pumpout condenser water.
c. Turn on the pumpout compressor to push the
refrigerant out of the chiller condenser.
d. When all liquid refrigerant is out of the chiller
condenser, close the cooler isolation valve 11.
1a 1b 2
C C C
3
C
4
C
5
C
8 11 12 13 14
C
10. Proceed to the TERMINATE LOCKOUT screen
(accessed from the CONTROL TEST table) to turn off
the water pumps and enable the chiller compressor for
start-up. If the chiller water pumps are not controlled
by the PIC II, turn them off manually.
70
Chillers with Storage Tanks — If the chiller has a
k. Close valves 1a, 1b, 2, 5, 6, and 10.
separate storage tank, or the chiller does not have isolation
valves, refer to the following procedure. See Fig. 32-35.
TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
1. Equalize refrigerant pressure.
a. Use the PIC II terminate lockout function on the
PUMPDOWN LOCKOUT screen, accessed from
the CONTROL TEST table to turn on the water
pumps and monitor pressures.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
l. Turn off pumpout condenser water.
TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C C
C C
CONDITION
b. Slowly open valve 5. When the pressures are
equalized, open liquid line valve 7 to allow liquid
refrigerant to drain by gravity into the pumpout
storage tank.
If the chilled water and condenser water pumps are not
controlled by the PIC II, these pumps must be started and
stopped manually at the appropriate times during the refrigerant transfer procedure.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
C
CONDITION
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and
close chiller charging valve 7; open chiller isolation valves 11, 12, 13, and 14 (if present).
c. Open pumpout unit/storage tank valves 3 and 6,
open chiller valves 1a and 1b.
2. Transfer the remaining liquid.
a. Turn off the pumpout condenser water. Place the
valves in the following positions:
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C C
C C C
CONDITION
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
C
CONDITION
b. Run the pumpout compressor for approximately
30 minutes; then close valve 10.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
C C
CONDITION
Follow steps D and E carefully to prevent damage from
freeze-up.
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
a. Turn on the chiller water pumps using the PUMPDOWN LOCKOUT screen, accessed from the
CONTROL TEST table. Turn on the pumps manually, if they are not controlled by the PIC II.
b. Turn on the pumpout condenser water.
c. Place valves in the following positions:
d. Slowly open valve 5 to increase chiller pressure to
68 psig 35 psig (141 kPa) for HFC-134a. Feed
refrigerant slowly to prevent freeze up.
e. Open valve 5 fully after the pressure rises above
the freeze point of the refrigerant. Open liquid
line valves 7 and 10 until refrigerant pressure
equalizes.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
C
CONDITION
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
C C
CONDITION
2. Transfer the remaining refrigerant.
a. Close valve 5 and open valve 4.
d. Run the pumpout compressor until the chiller
pressure reaches 30 psig (207 kPa) for HFC-134a.
Then, shut off the pumpout compressor. Warm
condenser water will boil off any entrapped liquid
refrigerant and the chiller pressure will rise.
e. When the pressure rises to 40 psig (276 kPa) for
HFC-134a, turn on the pumpout compressor until
the pressure again reaches 30 psig (207 kPa), and
then turn off the pumpout compressor. Repeat this
process until the pressure no longer rises. Then,
turn on the pumpout compressor and pump until
the pressure reaches18 in. Hg. (40 kPa absolute).
f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
CONDITION
b. Turn off the chiller water pumps using the CVC
(or manually, if necessary).
c. Turn off the pumpout condenser water, and turn
on the pumpout compressor to push liquid out of
the storage tank.
d. Close liquid line valve 7.
e. Turn off the pumpout compressor.
f. Close valves 3 and 4.
g. Open valves 2 and 5.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
C C
CONDITION
g. Turn off the pumpout condenser water and continue to use the PIC II PUMPDOWN LOCKOUT
screen functions, which lock out the chiller compressor for operation.
4. Establish a vacuum for service.
To conserve refrigerant, operate the pumpout compressor until the chiller pressure is reduced to 18 in. Hg
vac., ref 30 in. bar. (40 kPa abs.) following Step 3e.
h. Turn on the pumpout condenser water.
i. Run the pumpout compressor until the pumpout
storage tank pressure reaches 5 psig (34 kPa)
(18 in. Hg [40 kPa absolute] if repairing the tank).
j. Turn off the pumpout compressor.
71
GENERAL MAINTENANCE
should be repaired during annual maintenance or whenever the
refrigerant is pumped over for other service work.
Refrigerant Properties — HCFC-22 and HFC-134a
are the standard refrigerants in the 23XL. At normal atmospheric pressure, HCFC-22 will boil at –41 F (–40.5 C) and
HFC-134a will boil at –14 F (–25 C), and must, therefore, be
kept in pressurized containers or storage tanks. The refrigerants
are practically odorless when mixed with air. Both refrigerants
are non-combustible at atmospheric pressure. Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for
Mechanical Refrigeration to learn more about safe handling of
these refrigerants.
Test After Service, Repair, or Major Leak — If
all refrigerant has been lost or if the chiller has been opened for
service, the chiller or the affected vessels must be pressured
and leak tested. Refer to the Leak Test Chiller section to perform a leak test.
HCFC-22 and HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation.
In handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
HCFC-22 and HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation.
In handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.
TO PRESSURIZE WITH DRY NITROGEN — Another method of leak testing is to pressure with nitrogen only and
use soap bubble solution or an ultrasonic leak detector to determine if leaks are present. This should only be done if all refrigerant has been evacuated from the vessel.
1. Connect a copper tube from the pressure regulator on
the cylinder to the refrigerant charging valve. Never
apply full cylinder pressure to the pressurizing line.
Follow the listed sequence.
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level.
Do not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the
copper tube if no longer required.
Adding Refrigerant — Follow the procedures described
in the Charge Refrigerant into Chiller section, page 64.
Always use the compressor pumpdown function in the
Control Test mode to turn on the evaporator pump and lock
out the compressor when transferring refrigerant. Liquid
refrigerant may flash into a gas and cause possible freezeup when the chiller pressure is below 65 psig (448 kPa)
[30 psig (207 kPa)].
Removing Refrigerant — If the optional pumpout system is used, the 23XL refrigerant charge may be transferred to
a storage vessel or within the condenser or cooler if isolation
valves are present. Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing refrigerant from the storage tank to the chiller.
Repair the Refrigerant Leak, Retest, and
Apply Standing Vacuum Test — After pressurizing
the chiller, test for leaks with a soap bubble solution, an electronic leak detector, a halide torch, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any
leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum test. Then dehydrate the chiller. Refer to the Chiller Dehydration in the Before Initial Start-Up section, page 58.
Adjusting the Refrigerant Charge — If the addition or removal of refrigerant is required for improved chiller
performance, follow the procedures given under the Trim Refrigerant Charge section, on this page.
Refrigerant Leak Testing — Because HCFC-22 and
HFC-134a are above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the chiller. Use an electronic leak detector, halide leak detector, soap
bubble solution, or ultra-sonic leak detector. Be sure that the
room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any
necessary repairs to a leak, transfer all refrigerant from the
leaking vessel.
Trim Refrigerant Charge — If it becomes necessary
to adjust the refrigerant charge to obtain optimum chiller performance, operate the chiller at design load and then add or remove refrigerant slowly until the difference between leaving
chilled water temperature and the cooler refrigerant temperature reaches design conditions. Do not overcharge. For superheat information, see the Troubleshooting section on page 76.
Refrigerant may be added either through the optional storage tank or directly into the chiller as described in the section
entitled, Refrigerant Charging.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a, b on page 71.
Refrigerant Leak Rate — ASHRAE recommends that
chillers should be immediately taken off line and repaired if the
refrigerant leakage rate for the entire chiller is more than 10%
of the operating refrigerant charge per year.
Additionally, Carrier recommends that leaks totalling less
than the above rate but more than a rate of 1 lb (0.5 kg) per year
72
WEEKLY MAINTENANCE
yearly oil analysis is performed, the time between oil changes
may be extended. The 23XL TC frame 1 and 2 chillers use
approximately 4.2 gal (15.9 L) of oil. The 23XL TD frame 4
chillers use approximately 10 gal (38 L) of oil. See Oil Specification section on page 74 for additional information.
Check the Lubrication System — Mark the oil level on the sight glasses and observe the level each week while
the chiller is shut down.
If the level goes below the sight glass, the oil reclaim system will need to be checked for proper operation. If additional
oil is required, add it through the oil charging valve (Fig. 2A
and 2B). A hand pump is required for adding oil against refrigerant pressure. The oil charge is approximately 4.2 gal (15.9 L)
for TC frame 1 and 2 chillers and 10 gal (38 L) for TD frame 4
chillers. The oil must meet Carrier’s specifications for the
23XL chillers. Refer to Changing Oil and Oil Filter section.
Any oil that is added should be logged by noting the amount
and date in Fig. 37 on page 68. Any oil that is added due to oil
loss not related to service will eventually return to the sump. It
must be removed when the level is above the sight glass.
NOTE: TD frame 4 chillers do not use an oil heater.
On TC frame 1 and 2 chillers, a 500-watt oil heater is controlled by the PIC II to maintain oil temperature above 140 F
(60 C) [120 F (48.9 C)] or refrigerant temperature plus 35 F
(19 C) when the compressor is off (see the Controls section on
page 13). The CVC Status-COMPRESS table displays whether
the heater is energized or not. If the PIC II shows that the heater
is energized, but the sump is not heating up, the power to the oil
heater may be off or the oil level may be too low. Check the oil
level, the oil heater contactor voltage, and oil heater resistance.
The PIC II will not permit compressor start-up if the oil
temperature is too low (TC fame 1 and 2 chillers). The control
will continue with start-up only after the temperature is within
limits.
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
TC FRAME 1 AND 2 CHILLERS — The 23XL oil sump
can be isolated to change the oil filter and oil while the refrigerant remains inside the chiller. Use the following procedure to
change the oil and oil filter (if required):
IMPORTANT: Remove oil from TC frame 1 and 2 chillers before changing the oil filter. Refer to Fig. 2A and 3.
1. Make sure the compressor is off and the disconnect for
the compressor is open.
2. Open the control and oil heater circuit breaker in order
to turn off the power to the oil heater.
3. Close the 3 oil sump isolation valves. One isolation
valve is upstream and one isolation valve is downstream of the oil sump. The third isolation valve is in
the oil sump vent line.
Be sure the power to the oil heater is off when the oil sump
is isolated and full. If the oil heater remains energized,
over-pressurization of the oil sump could result in the failure of the oil solenoid valve, discharge of hot oil, and personal injury.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered
as guides to service only.
Inspect the Control Panel — Maintenance is general-
4. Connect an oil charging hose to the oil drain valve. See
Fig. 3. Place the other end of the oil charging hose in a
clean container suitable for used oil. A portion of the
oil drained from the sump should be used as an oil
sample and should be sent to a laboratory for proper
analysis. Do not contaminate this sample.
5. Slowly open the drain valve in order to drain the oil
from the sump.
ly limited to general cleaning and tightening of connections.
Vacuum the cabinet to eliminate dust build-up. In the event of
chiller control malfunctions, refer to the Troubleshooting
Guide section for control checks and adjustments.
The oil sump is at high pressure. Relieve pressure slowly.
Service Ontime — The CVC will display a SERVICE
ONTIME value on the MAINSTAT table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between service
can be seen.
6. Once the oil has been drained, place absorbent material under the oil sump to catch any oil that may leak
out once the oil sump cover is opened. Continue with
Steps 7, 8, and 9 if a new oil filter is required. Proceed
to Step 10 if no oil filter change is required.
7. Remove the 6 bolts from the end of the oil sump and
remove the oil sump cover.
8. Remove the oil filter retaining spring. Remove and
properly discard the oil filter.
9. Insert a new oil filter. Seat the filter retaining spring
against the flange stop. Install the oil sump cover with
a new O-ring. Insert and tighten the 6 bolts that secure
the oil sump cover.
10. Evacuate the oil sump by placing a vacuum pump on
the drain valve. Follow normal evacuation procedures.
Shut off the drain valve when the oil sump has been
evacuated. Charge new oil through the drain valve.
Be sure power to the control panel is off when cleaning and
tightening connections inside the control panel.
Check Safety and Operating Controls
Monthly — To ensure chiller protection, the Automated
Control Test in the service menu should be done at least once
per month. See Table 4 for safety control settings.
Changing Oil and Oil Filter — If the pressure drop
across the filter has approached the OIL FILTER PRESS
ALERT value on the Equipment Service, Service1 table,
change oil filter as needed. Otherwise, change the oil filter on a
yearly basis.
Change the oil after the first year of operation. Then,
change the oil at least every three years, or as needed. However, if a continuous oil monitoring system is present and/or a
73
•
•
•
•
•
11. Add oil (approximately 4.2 gal [15.9 L]) until it can be
seen at the lower edge of the oil sump sight glass. The
oil sight glass will not fill completely since a small
amount of gas will be trapped inside, even under vacuum conditions.
12. Open all 3 isolation valves (previously closed in
Step 3). Apply power to the controls and oil heater.
13. The oil level will rise once the refrigerant gets
absorbed into the oil.
TD FRAME 4 CHILLERS — Use the following procedures
to change the oil filter and/or oil on TD frame 4 chillers. Oil
can remain in TD frame 4 chillers when changing the oil filter.
Refer to Fig. 2B and 4.
Changing Oil Filter
1. Make sure the compressor is off and the disconnect for
the compressor starter is open.
2. Close both oil filter isolation valves. See Fig. 4.
3. Place a container underneath the oil filter assembly.
4. Slowly open the vent plug, located on top of the oil filter housing, to relieve pressure. Do not remove the
plug. When a Schrader valve is provided, use it to
relieve the pressure.
5. Remove the filter canisters by unscrewing the retainer
nut. The filter may now be removed and disposed of
properly.
6. Install new oil filter. Install the new O-ring. Tighten
the retainer nut.
7. Partially open the isolation valve located near the oil
separator. Bleed the excess air from the vent plug.
Once oil starts escaping from the vent plug, close the
isolation valve. Tighten the vent plug on top of the oil
filter housing.
8. If a Schrader valve is supplied, evacuate the oil filter
by connecting the vacuum pump to the Schrader valve.
Changing Oil
NOTE: A hand pump or portable electric oil pump will be
required to complete the following operation.
1. Transfer the refrigerant into the condenser (for vessel
that can be isolated) or storage tank.
2. When the chiller pressure equals a maximum of 5 psi
(34 kPa), drain the oil by opening the oil charging
valve, located on the bottom of the oil separator.
3. Change the oil filter as described in the Changing Oil
Filter section for TD frame 4 chillers.
4. Charge the oil separator with approximately 10 gal
(39 L) of oil. The oil level should be in the center of
the lower sight glass.
Pour Point (maximum) . . . . . . . . . . . . . . . . . . . –6 F (–21 C)
Flash Point (minimum) . . . . . . . . . . . . . . . . . . 428 F (220 C)
Moisture Content (maximum). . . . . . . . . . . . . . . . . .100 ppm
Acid Number (maximum) . . . . . . . . . . . . 0.5 mg KOH/gram
Miscibility Range with HCFC-22 . . . . . . . . . . . .–90 to 200 F
(–68 to 93 C)
with HFC-134a . . . . . . . . . . . . . .–4 to 180 F
(–2 to 82 C)
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
This oil (part number PP-23-BZ-104) may be ordered from
your local Carrier representative.
Oil Separator Coalescer
TC FRAME 1 AND 2 CHILLERS — The oil separator coalescing element is replaceable and has an estimated life of
15 years. Proper maintenance procedures require the coalescer
to be changed approximately 100 hours after a major compressor teardown or chiller overhaul.
TD FRAME 4 CHILLERS — TC frame 4 chillers do not
have a replaceable oil coalescer.
Refrigerant Filter/Drier — A refrigerant filter/drier, located on the motor cooling line should be changed once a year,
or as necessary, if filter condition indicates a need for less or
more frequent replacement. Change the filter with the chiller
pressure at 0 psig (0 kPa) by transferring the refrigerant to the
condenser vessel, (if isolation valves are present) or a storage
tank. A moisture indicator (dry eye) sight glass is located beyond this filter to indicate the volume of moisture in the refrigerant. If the moisture indicator indicates moisture, locate the
source of water immediately by performing a thorough leak
check.
Refrigerant Strainers (TC Frame 1 and 2 Chillers Only) — The oil reclaim system has two strainers. One
is located on the eductor suction line, and one on the condenser
gas line. Replace these strainers once per year, or as necessary
if strainer condition indicates a need for less or more frequent
replacement. Change these strainers with the cooler/compressor vessel at 0 psig (0 kPa) by transferring the refrigerant
charge to a storage vessel or the condenser.
Inspect Refrigerant Float System — Perform this
inspection every 5 years or when the condenser is opened for
service.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
2. Remove the float access cover.
3. Clean the chamber and valve assembly thoroughly. Be
sure the valve moves freely. Ensure that all openings
are free of obstructions.
4. Examine the cover gasket and replace if necessary.
See Fig. 40 for a view of the float valve design. For linear
float valve designs, inspect the orientation of the float slide
pin. It must be pointed toward the bubbler tube for proper
operation.
Oil Specification — If oil is to be added, it must meet the
following Carrier specifications:
• Carrier Part Number. . . . . . . . . . . . . . . . . . . . . . . PP23BZ104
• Oil type . . . . . . . . . . . . . . . . . . . . Inhibited polyolester-based
synthetic compressor lubricant suitable for use
in screw compressors where high viscosity
and compatibility with HCFC-22 and HFC-134a
refrigerants is required.
• ISO Viscosity Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
• Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.981
• Viscosity, cSt at 40 C (104 F) . . . . . . . . . . . . . . . . 210 to 230
cSt at 100 C (212 F) . . . . . . . . . . . . . . . . . 18 to 21
SSU at 100 F (38 C) . . . . . . . . . . . . . . . .1005 ± 45
SSU at 210 F (99 C) . . . . . . . . . . . . . . . . . . . 91 ± 7
• Floc Point (maximum). . . . . . . . . . . . . . . . . . . –90 F (–68 C)
Inspect Relief Valves and Piping — The relief valves on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against
damage to the equipment and possible injury to personnel,
these devices must be kept in peak operating condition.
74
1
2
3
4
5
6
7
8
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temperature sensors for signs of corrosion or scale. Replace the
sensor if corroded or remove any scale if found.
CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and
scale. Clean the condenser tubes with a rotary tube cleaning
system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water
sensors for signs of corrosion or scale. Replace the sensor if
corroded or remove any scale if found.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a rise
above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is
supposed to be, then the condenser tubes may be dirty or water
flow may be incorrect. Because HCFC-22 and HFC-134a are
high-pressure refrigerants, air usually does not enter the chiller;
instead the refrigerant leaks out.
During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact
your Carrier representative to obtain these brushes. Do not use
wire brushes.
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubble Line
Float Cover
Bubble Line Connection
Refrigerant Outlet to Cooler
Gasket
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for
proper treatment.
Water Leaks — Water is indicated during chiller opera-
Fig. 40 — 23XL Float Valve Design
tion by the refrigerant moisture indicator on the refrigerant motor cooling line. See Fig. 11 and 12. Water leaks should be repaired immediately.
As a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and
mechanism for any evidence of internal corrosion or
rust, dirt, scale, leakage, etc.
2. If corrosion or foreign material is found, do not
attempt to repair or recondition. Replace the valve.
3. If the chiller is installed in a corrosive atmosphere or
the relief valves are vented into a corrosive
atmosphere, make valve inspections at more frequent
intervals.
Chiller must be dehydrated after repair of water leaks. See
Chiller Dehydration section, page 58.
Water Treatment — Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.
Compressor Bearing Maintenance — The key to
good bearing maintenance is proper lubrication. Use the proper
grade of oil, maintained at recommended level, temperature,
and pressure. Inspect the lubrication system regularly and
thoroughly.
Excessive bearing wear can be detected through increased
vibration. If this symptom appears, contact an experienced and
responsible service organization to perform vibration analysis
on the compressor.
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and to reduce the
potential of tubing damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water.
Inspect the Starting Equipment — Before working
Compressor Rotor Check — Use Carrier specified
on any starter, shut off the chiller, and open all disconnects supplying power to the starter.
oil. Excessive compressor rotor wear is shown by a lack of performance. If a lack of performance is noted, have the compressor rotors inspected by a trained service person.
The rotors can be visually inspected once every 5 to
10 years or as needed depending on chiller operating
conditions.
The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.
Inspect the Heat Exchanger Tubes
COOLER — Inspect and clean the cooler tubes at the end of
the first operating season. Because these tubes have internal
ridges, a rotary-type tube cleaning system is necessary to fully
clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate
whether water treatment is adequate in the chilled water/
brine circuit. Inspect the entering and leaving chilled water
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
75
Inspect starter contact surfaces for wear or pitting on mechanical-type starters. Do not sandpaper or file silverplated
contacts. Follow the starter manufacturer’s instructions for
contact replacement, lubrication, spare parts ordering, and other maintenance requirements.
Periodically vacuum or blow off accumulated debris on the
internal parts with a high-velocity, low-pressure blower.
Power connections on newly installed starters may relax
and loosen after a month of operation. Turn power off and retighten. Recheck annually thereafter.
Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.
Check Pressure Transducers — Once a year, the
pressure transducers should be checked against a pressure gage
reading. Check all 7 transducers: the oil pressure transducer,
the condenser pressure transducer, the cooler pressure transducer, and the waterside pressure transducers (consisting of 4
flow devices: 2 cooler, 2 condenser).
Note the evaporator and condenser pressure readings on the
HEAT_EX screen on the CVC (EVAPORATOR PRESSURE
and CONDENSER PRESSURE). Attach an accurate set of refrigeration gages to the cooler and condenser Schrader fittings.
Compare the two readings. If there is a difference in readings,
the transducer can be calibrated as described in the Troubleshooting Guide section. Oil differential pressure (OIL PUMP
DELTA P on the COMPRESS screen) should be zero whenever the compressor is off.
Fig. 41 — Optional Pumpout System Controls
Check the switch setting by operating the pumpout compressor
and slowly throttling the pumpout condenser water.
Ordering Replacement Chiller Parts — When ordering Carrier specified parts, the following information must
accompany an order.
• chiller model number and serial number
• name, quantity, and part number of the part required
• delivery address and method of shipment
Optional Pumpout System Maintenance — For
compressor maintenance details, refer to the 06D, 07D Installation, Start-Up, and Service Instructions.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocating
compressor usage. Oil requirements are as follows:
• HCFC-22 and HFC-134a
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• Viscosity SSU 100 F (38 C) . . . . . . . . . . . . . . . . . . . 300
• Carrier Part Number . . . . . . . . . . . . . . . . . . PP23BZ-103
The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints
(2.0 L) for the compressor and one additional pint (0.6 L) for
the oil separator.
Oil should be visible in one of the compressor sight glasses
during operation and at shutdown. Always check the oil level
before operating the compressor. Before adding or changing
oil, relieve the refrigerant pressure as follows:
1. Attach a pressure gage to the gage port of either compressor service valve.
2. Close the suction service valve and open the discharge
line to the storage tank or the chiller.
3. Operate the compressor until the crankcase pressure
drops to 2 psig (13 kPa).
4. Stop the compressor and isolate the system by closing
the discharge service valve.
5. Slowly remove the oil return line connection (Fig. 39).
Add oil as required.
6. Replace the connection and reopen the compressor
service valves.
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 41) — The optional pumpout system high-pressure
switch should open at 220 ± 5 psig (1517 ± 34 kPa) and should
reset automatically on pressure drop to 190 psig (1310 kPa) for
HCFC-22 chillers. For chillers using HFC-134a, the switch
opens at 161 psig (1110 kPa) and closes at 130 psig (896 kPa).
TROUBLESHOOTING GUIDE
Overview — The PIC II has many features to help the operator and technician troubleshoot a 23XL chiller.
• The CVC shows the chiller’s actual operating conditions
and can be viewed while the unit is running.
• The CVC default screen freezes when an alarm occurs.
The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS screens continue
to show current information. Once all alarms have been
cleared (by correcting the problems and pressing the
RESET softkey), the CVC default screen returns to
normal operation.
• The CONTROL ALGORITHM STATUS screens
(which include the CAPACITY, OVERRIDE,
LL_MAINT, ISM_HIST, LOADSHED, WSMCHLRS,
and OCCDEFCM screens) display information that
helps to diagnose problems with chilled water temperature control, chilled water temperature control overrides,
hot gas bypass, surge algorithm status, and time schedule operation.
• The Control Test feature facilitates the proper operation
and test of temperature sensors, pressure transducers, the
guide vane actuator, oil pump, water pumps, tower control, and other on/off outputs while the compressor is
stopped. It also has the ability to lock off the compressor
and turn on water pumps for pumpout operation. The
CVC shows the temperatures and pressures required
during these operations.
• From other SERVICE tables, the operator or technician
can access configured items, such as chilled water resets,
override set points, etc.
76
•
Checking Pressure Transducers — There are 8
pressure transducers on 23XL chillers. They determine cooler,
condenser, oil pressure, and cooler and condenser flow. The
cooler and condenser transducers are also used by the PIC II to
determine the refrigerant temperatures. The oil pressure valve
(oil pressure transducer — evap pressure transducer) is calculated by the CCM.
All pressure transducers should be calibrated prior to initial
start-up. However, at high altitude locations, it is necessary to
calibrate the transducers to ensure the proper refrigerant
temperature/pressure relationship. Each transducer is supplied
with 5 vdc power from the CCM. If the power supply fails, a
transducer voltage reference alarm occurs. If the transducer
reading is suspected of being faulty, check the supply voltage.
It should be 5 vdc ± .5 v displayed in CONTROL TEST under
CCM Pressure Transducers. If the supply voltage is correct, the
transducer should be recalibrated or replaced.
COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION —
Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the
HEAT_EX screen on the CVC. The transducer can be checked
and calibrated at 2 pressure points. These calibration points
are 0 psig (0 kPa) and between 25 and 250 psig (173 and
1724 kPa). To calibrate these transducers:
1. Shut down the compressor, cooler, and condenser
pumps.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its
Schrader fitting for cooler or condenser transducer calibration. For oil pressure or flow device calibration
keep transducer in place.
NOTE: If the cooler or condenser vessels are at
0 psig (0 kPa) or are open to atmospheric pressure, the
transducers can be calibrated for zero without removing the transducer from the vessel.
3. Access the HEAT_EX screen and view the particular
transducer reading (the EVAPORATOR PRESSURE or
CONDENSER PRESSURE parameter on the
HEAT_EX screen). To calibrate oil pressure or waterside flow device, view the particular reading
(CHILLED WATER DELTA P and CONDENSER
WATER DELTA P on the HEAT_EX screen, and OIL
PUMP DELTA P on the COMPRESS screen). It
should read 0 psi (0 kPa). If the reading is not 0 psi
(0 kPa), but within ± 5 psi (35 kPa), the value may be
set to zero by pressing the SELECT softkey while the
appropriate transducer parameter is highlighted on the
CVC screen. Then press the ENTER softkey. The
value will now go to zero. No high end calibration is
necessary for OIL PUMP DELTA P or flow devices.
If the transducer value is not within the calibration
range, the transducer returns to the original reading. If
the pressure is within the allowed range (noted above),
check the voltage ratio of the transducer. To obtain the
voltage ratio, divide the voltage (dc) input from the
transducer by the supply voltage signal (displayed in
CONTROL TEST menu in the CCM PRESSURE
TRANSDUCERS screen) or measure across the positive (+ red) and negative (– black) leads of the transducer. For example, the condenser transducer voltage
input is measured at CCM terminals J2-4 and J2-5.
The voltage ratio must be between 0.80 and 0.11 for
the software to allow calibration. Pressurize the transducer until the ratio is within range. Then attempt calibration again.
If an operating fault is detected, an alarm message is
generated and displayed on the CVC default screen. A
more detailed message — along with a diagnostic message — is also stored into the ALARM HISTORY table.
Checking Display Messages — The first area to
check when troubleshooting the 23XL chiller is the CVC display. If the alarm light is flashing, check the primary and secondary message lines on the CVC default screen (Fig. 17).
These messages will indicate where the fault is occurring.
These messages contain the alarm message with a specified
code. This code or state appears with each alarm and alert message. The ALARM HISTORY table on the CVC SERVICE
menu also contains an alarm message to further expand on the
alarm. For a complete list of possible alarm messages, see Table 9. If the alarm light starts to flash while accessing a menu
screen, press the EXIT softkey to return to the default screen
to read the alarm message. The STATUS screen can also be accessed to determine where an alarm exists.
Checking Temperature Sensors — All
temperature sensors are thermistor-type sensors. This means that the resistance of the sensor varies with temperature. All sensors have
the same resistance characteristics. If the controls are on, determine sensor temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in
Table 10A or 10B.
RESISTANCE CHECK — Turn off the control power and,
from the module, disconnect the terminal plug of the sensor in
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram.
The resistance and corresponding temperature are listed in
Table 10A or 10B. Check the resistance of both wires to
ground. This resistance should be infinite.
VOLTAGE DROP — The voltage drop across any energized
sensor can be measured with a digital voltmeter while the control is energized. Table 10A or 10B lists the relationship between temperature and sensor voltage drop (volts dc measured
across the energized sensor). Exercise care when measuring
voltage to prevent damage to the sensor leads, connector plugs,
and modules. Sensors should also be checked at the sensor
plugs. Check the sensor wire at the sensor for 5 vdc if the control is powered on.
Relieve all refrigerant pressure or drain the water before
replacing the temperature sensors.
CHECK SENSOR ACCURACY — Place the sensor in a
medium of known temperature and compare that temperature
to the measured reading. The thermometer used to determine
the temperature of the medium should be of laboratory quality
with 0.5º F (.25º C) graduations. The sensor in question should
be accurate to within 2º F (1.2º C).
See Fig. 11 and 12 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring
at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the
sensor. When installing a new sensor, apply a pipe sealant or
thread sealant to the sensor threads.
DUAL TEMPERATURE SENSORS — For servicing convenience, there are 2 sensors on the motor temperature sensor.
If one of the sensors is damaged, the other can be used by simply moving a wire. The number 2 terminal in the sensor terminal box is the common line. To use the second sensor, move the
wire from the number 1 position to the number 3 position.
77
Control Algorithms Checkout Procedure —
4. A high pressure point can also be calibrated between
25 and 250 psig (172.4 and 1723.7 kPa) by attaching a
regulated 250 psig (1724 kPa) pressure (usually from a
nitrogen cylinder). The high pressure point can be calibrated by accessing the appropriate transducer parameter on the HEAT_EX screen, highlighting the
parameter, pressing the SELECT softkey, and then
using the INCREASE or DECREASE softkeys to
adjust the value to the exact pressure on the refrigerant
gage. Press the ENTER softkey to finish the calibration. Pressures at high altitude locations must be compensated for, so the chiller temperature/pressure
relationship is correct.
One of the tables on the CVC SERVICE menu is CONTROL
ALGORITHM STATUS. The maintenance screens may be
viewed from the CONTROL ALGORITHM STATUS table to
see how a particular control algorithm is operating.
These maintenance screens are very useful in helping to determine how the control temperature is calculated and guide
vane positioned and for observing the reactions from load
changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are:
The PIC II does not allow calibration if the transducer is too
far out of calibration. In this case, a new transducer must be installed and re-calibrated.
TRANSDUCER REPLACEMENT — Since the transducers
are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring by pulling up on the
locking tab while pulling up on the weather-tight connecting
plug from the end of the transducer. Do not pull on the transducer wires. Unscrew the transducer from the Schrader fitting.
When installing a new transducer, do not use pipe sealer
(which can plug the sensor). Put the plug connector back on the
sensor and snap into place. Check for refrigerant leaks.
CAPACITY
Capacity
Control
OVERRIDE
Override
Status
Surge/HGBP
Status
HEAT_EX
LL_MAINT
OCCDEFCM
WSMDEFME
Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducer, since the Schrader fitting
may back out with the transducer, causing a large leak and
possible injury to personnel.
LEAD/LAG
Status
Time
Schedules
Status
Water
System
Manager
Status
This table shows all values
used to calculate the chilled
water/brine control point.
Details of all chilled water control override values.
The surge and hot gas bypass
control algorithm status is
viewed from this screen. All
values dealing with this control
are displayed.
Indicates LEAD/LAG operation status.
The Local and CCN occupied
schedules are displayed here
to help the operator quickly
determine whether the schedule is in the “occupied” mode
or not.
The water system manager is
a CCN module that can turn
on the chiller and change the
chilled water control point.
This screen indicates the
status of this system.
Control Test — The Control Test feature can check all the
thermistor temperature sensors, pressure transducers, pumps
and their associated flow devices, the slide valve, and other
control outputs such as hot gas bypass. The tests can help to determine whether a switch is defective or a pump relay is not operating, as well as other useful troubleshooting issues. During
pumpdown operations, the pumps are energized to prevent
freeze-up and the vessel pressures and temperatures are displayed. The Pumpdown/Lockout feature prevents compressor
start-up when there is no refrigerant in the chiller or if the vessels are isolated. The Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
LEGEND TO TABLES 9A-9J
CM
CCN
CVC
CHW
ISM
PIC II
VFD
78
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—
—
—
—
—
—
Chiller Control Module
Carrier Comfort Network
Chiller Visual Controller
Chilled Water
Integrated Starter Module
Product Integrated Control II
Variable Frequency Drive
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE
MANUALLY STOPPED — PRESS
TERMINATE PUMPDOWN MODE
SECONDARY MESSAGE
CCN OR LOCAL TO START
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
COMPRESSOR DEENERGIZED
ICE BUILD
OPERATION COMPLETE
PROBABLE CAUSE/REMEDY
PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
Enter the CONTROL TEST table and select TERMINATE
LOCKOUT to unlock compressor.
Chiller unloading before shutdown due to soft/stop feature.
Chiller compressor is being commanded to stop. Water pumps
are deenergized within one minute.
Chiller shutdown from Ice Build operation.
B. READY TO START
PRIMARY MESSAGE
READY TO START IN XX MIN
SECONDARY MESSAGE
UNOCCUPIED MODE
READY TO START IN XX MIN
READY TO START IN XX MIN
REMOTE CONTACTS OPEN
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START IN XX MIN
OCCUPIED MODE
REMOTE CONTACTS CLOSED
READY TO START IN XX MIN
START COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START
RECYCLE RESTART PENDING
UNOCCUPIED MODE
READY TO START
READY TO START
REMOTE CONTACTS OPEN
STOP COMMAND IN EFFECT
READY TO START
READY TO START
READY TO START
OCCUPIED MODE
REMOTE CONTACTS CLOSED
START COMMAND IN EFFECT
STARTUP INHIBITED
LOADSHED IN EFFECT
PROBABLE CAUSE/REMEDY
Time schedule for PIC II is unoccupied. Chillers will start only when
occupied.
Remote contacts are open. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop.
Release point to start.
Chiller timer counting down. Unit ready to start.
Chiller timer counting down. Unit ready to start. Remote contact
enabled and closed.
Chiller START/STOP on MAINSTAT manually forced to start.
Release value to start under normal control.
Chiller in recycle mode.
Time schedule for PIC II is unoccupied. Chiller will start when occupied. Make sure the time and date are correct. Change values in
TIME AND DATE screen.
Remote contacts have stopped the chiller. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop.
Release point to start.
Chiller timers complete, unit start will commence.
Chiller timer counting down. Unit ready for start.
Chiller START/STOP on MAINSTAT has been manually forced to
start. Chiller will start regardless of time schedule or remote contact
status.
CCN loadshed module commanding chiller top stop.
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
RECYCLE RESTART PENDING
SECONDARY MESSAGE
OCCUPIED MODE
RECYCLE RESTART PENDING
REMOTE CONTACT CLOSED
RECYCLE RESTART PENDING
START COMMAND IN EFFECT
RECYCLE RESTART PENDING
ICE BUILD MODE
79
PROBABLE CAUSE/REMEDY
Unit in recycle mode, chilled water temperature is not sufficiently
above set point to start.
Unit in recycle mode, chilled water temperature is not sufficiently
above set point to start.
Chiller START/STOP on MAINSTAT manually forced to start,
chilled water temperature is not sufficiently above set point to start.
Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied
for ICE BUILD conditions.
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue.
No reset is necessary.
PRIMARY
MESSAGE
PRESTART
ALERT
PRESTART
ALERT
SECONDARY
MESSAGE
STARTS LIMIT
EXCEEDED
HIGH MOTOR
TEMPERATURE
ALARM MESSAGE
PRIMARY CAUSE
100->Excessive compressor
starts (8 in 12 hours)
102->Comp Motor Winding
Temp [VALUE] exceeded limit
of [LIMIT]*.
103
PRESTART
ALERT
HIGH DISCHARGE
TEMP
103->Comp Discharge Temp
[VALUE] exceeded limit of
[LIMIT]*.
104
PRESTART
ALERT
LOW REFRIGERANT
TEMP
105
PRESTAR
ALERT
PRESTART
ALERT
LOW OIL
TEMPERATURE
HIGH CONDENSER
PRESSURE
107
PRESTART
ALERT
LOW LINE
VOLTAGE
108
PRESTART
ALERT
HIGH LINE
VOLTAGE
104->Evaporator Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.
105->Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.
106->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
107->Average Line Voltage
[VALUE] exceeded limit of
[LIMIT]*.
108->Average Line Voltage
[VALUE] exceeded limit of
[LIMIT]*.
STATE
100
102
106
ADDITIONAL CAUSE/REMEDY
Depress the RESET softkey if additional start is
required. Reassess start-up requirements.
Check motor sensors for wiring and accuracy.
Check motor cooling line for proper operation, or
restrictions.
Check for excessive starts within a short time
span.Check configurable range in SETUP1 screen.
Allow discharge sensor to cool.
Check for sensor wiring and accuracy.
Check for excessive starts.
Check configurable range in SETUP1 screen.
Check transducer wiring and accuracy.
Check for low chilled fluid supply temperatures.
Check refrigerant charge.
Check oil heater contactor/relay and power.
Check oil level and oil pump operation.
Check transducer wiring and accuracy.
Check for high condenser water temperatures.
Check voltage supply. Check voltage transformers.
Consult power utility if voltage is low.
Check voltage supply.
Check power transformers.
Consult power utility if voltage is high.
*[LIMIT] is shown on the CVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is
the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP IN PROGRESS
PRIMARY MESSAGE
STARTUP IN PROGRESS
STARTUP IN PROGRESS
STARTUP IN PROGRESS
SECONDARY MESSAGE
OCCUPIED MODE
REMOTE CONTACT CLOSED
START COMMAND IN EFFECT
AUTORESTART IN PROGRESS
AUTORESTART IN PROGRESS
OCCUPIED MODE
REMOTE CONTACT CLOSED
AUTORESTART IN PROGRESS
START COMMAND IN EFFECT
CAUSE/REMEDY
Chiller is starting. Time schedule is occupied.
Chiller is starting. Remote contacts are enabled and closed.
Chiller is starting. Chiller START/STOP in MAINSTAT manually
forced to start.
Chiller is starting after power failure. Time schedule is occupied.
Chiller is starting after power failure. Remote contacts are enabled
and closed.
Chiller is starting after power failure. Chiller START/STOP on
MAINSTAT manually forced to start.
80
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
F. NORMAL RUN
PRIMARY MESSAGE
RUNNING — RESET ACTIVE
RUNNING — RESET ACTIVE
RUNNING — RESET ACTIVE
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — TEMP CONTROL
SECONDARY MESSAGE
4-20 mA SIGNAL
REMOTE TEMP SENSOR
CHW TEMP DIFFERENCE
LEAVING CHILLED WATER
ENTERING CHILLED WATER
TEMPERATURE RAMP LOADING
BY DEMAND RAMP LOADING
BY LOCAL DEMAND SETPOINT
BY 4-20 mA SIGNAL
BY CCN SIGNAL
BY LOADSHED/REDLINE
HOT GAS BYPASS
RUNNING — DEMAND LIMITED
RUNNING —TEMP CONTROL
BY LOCAL SIGNAL
ICE BUILD MODE
CAUSE/REMEDY
Auto chilled water reset active based on external input.
Auto chilled water reset active based on external input.
Auto chilled water reset active based on cooler ∆T.
Default method of temperature control.
Entering Chilled Water (ECW) control enabled in TEMP_CTL screen
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Demand limit set point is less than actual demand.
Demand limit is active based on external auto demand limit option.
Demand limit is active based on control limit signal from CCN.
Demand limit is active based on LOADSHED screen set-up.
Hot gas bypass option is energized. See stall prevention in the control
section.
Active demand limit manually overridden on MAINSTAT table.
Chiller is running under Ice Build temperature control.
G. NORMAL RUN WITH OVERRIDES
PRIMARY
MESSAGE
RUN CAPACITY
LIMITED
SECONDARY
MESSAGE
HIGH CONDENSER
PRESSURE
121
RUN CAPACITY
LIMITED
HIGH MOTOR
TEMPERATURE
122
RUN CAPACITY
LIMITED
LOW EVAP
REFRIG TEMP
123
RUN CAPACITY
LIMITED
HIGH COMPRESSOR
LIFT
124
RUN CAPACITY
LIMITED
MANUAL SLIDE
VALVE
125
RUN CAPACITY
LIMITED
RUN CAPACITY
OVERRIDE
LOW DISCHARGE
SUPERHEAT
ROTOR INLET
TEMPERATURE
STATE
120
126
ALARM MESSAGE
PRIMARY CAUSE
120->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
121->Comp Motor Winding
Temp [VALUE] exceeded limit
of [LIMIT]*.
122->Evaporator Refrig
Temp [VALUE] exceeded limit
of [LIMIT]*.
123->Stall Prevention
Override: Lift Too High For
Compressor.
124->Run Capacity Limited:
Manual Slide Valve Control.
No messages.
ADDITIONAL CAUSE/REMEDY
Check for high condenser water temperatures.
Check setting in SETUP1.
Check motor cooling lines.
Check for closed valves.
Check setting in SETUP1.
Check refrigerant charge.
Check for low entering cooler temperatures.
Check for high condenser water temperatures
or low suction temperature.
Slide valve point has been forced in MAINSTAT
screen. Release force to continue normal
operation.
Check oil charge.
Check refrigerant charge.
126->Run Capacity Override:
Rotor Inlet Temp.
*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.
H. OUT-OF-RANGE SENSOR ALARMS
STATE
260
261
262
263
264
265
266
267
268
269
PRIMARY
MESSAGE
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SECONDARY
MESSAGE
LEAVING CHILLED
WATER
ENTERING CHILLED
WATER
CONDENSER
PRESSURE
EVAPORATOR
PRESSURE
ROTOR INLET
TEMP
COMPRESSOR
MOTOR TEMP
OIL SUMP
TEMP
COMP OIL
PRESS DIFF
CHILLED WATER
FLOW
COND WATER
FLOW
ALARM MESSAGE
PRIMARY CAUSE
260->Sensor Fault:
Leaving Chilled Water
261->Sensor Fault:
Entering Chilled Water
262->Sensor Fault:
Condenser Pressure
263->Sensor Fault:
Evaporator Pressure
264->Sensor Fault:
Rotor Inlet Temp
265->Sensor Fault:
Comp Motor Winding Temp
266->Sensor Fault:
Oil Sump Temp
267->Sensor Fault:
Oil Sump Temp
269->Sensor Fault:
Chilled Water Delta P
270->Sensor Fault:
Cond Water Delta P
81
ADDITIONAL CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor wiring.
Check sensor wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor wiring and accuracy.
Check sensor wiring and accuracy.
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
1M CONTACT
FAULT
201
PROTECTIVE
LIMIT
2M CONTACT
FAULT
202
PROTECTIVE
LIMIT
MOTOR AMPS
NOT SENSED
203
FAILURE TO
START
EXCESS
ACCELERATION
TIME
204
FAILURE TO
STOP
1M/2M CONTACT
FAULT
205
FAILURE TO
STOP
MOTOR AMPS
WHEN STOPPED
206
PROTECTIVE
LIMIT
STARTER
FAULT
207
PROTECTIVE
LIMIT
HIGH CONDENSER
PRESSURE
208
PROTECTIVE
LIMIT
EXCESSIVE
MOTOR AMPS
209
PROTECTIVE
LIMIT
LINE PHASE
LOSS
210
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
LINE VOLTAGE
DROPOUT
HIGH LINE
VOLTAGE
208->Compressor Motor
Amps [VALUE] exceeded
limit of[LIMIT]*.
209->Line Phase Loss;
Check ISM Fault History to
Identify Phase
210->Single Cycle Line
Voltage Dropout
211->High Average Line
Voltage [VALUE]
212
PROTECTIVE
LIMIT
LOW LINE
VOLTAGE
212->Low Average Line
Voltage [VALUE]
213
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
STARTER MODULE
RESET
POWER LOSS
213->Starter Module PowerOn Reset When Running
214->Power Loss:
Loss When Running
215
PROTECTIVE
LIMIT
LINE CURRENT
IMBALANCE
216
PROTECTIVE
LIMIT
LINE VOLTAGE
IMBALANCE
217
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
MOTOR OVERLOAD
TRIP
MOTOR LOCKED
ROTOR TRIP
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
STARTER LOCK
ROTOR TRIP
GROUND FAULT
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
PHASE REVERSAL
TRIP
LINE FREQUENCY
TRIP
PROTECTIVE
LIMIT
STARTER MODULE
FAILURE
215->Line Current
Imbalance; Check ISM Fault
History to Identify Phase
216->Line Voltage
Imbalance; Check ISM Fault
History to Identify Phase
217->Motor Overload Trip;
Check ISM configurations
218->Motor Locked Rotor
Amps exceeded; Check
Motor & ISM Config
219->Starter Locked Rotor
Amps Rating exceeded
220->Ground Fault Trip;
Check Motor and Current
Transformers
221->Phase Reversal Trip;
Check Power Supply
222->Line Frequency —
[VALUE] exceeded limit of
[LIMIT].* Check Power
Supply.
223->Starter Module
Hardware Failure
STATE
200
211
214
218
219
220
221
222
223
ALARM MESSAGE
PRIMARY CAUSE
200->1M Aux Contact Fault;
Check 1M Contactor and
Aux
201->2M Aux Contact Fault;
Check 2M Contactor and
Aux
202->Motor Amps Not
Sensed — Average Line
Current [VALUE]
203->Motor Acceleration
Fault — Average Line Current [VALUE]
204->1M/2M Aux Contact
Stop Fault; Check 1M/2M
Contactors and Aux
205->Motor Amps When
Stopped — Average Line
Current [VALUE]
206->Starter Fault Cutout;
Check Optional Starter
Contacts
207->High Cond Pressure
cutout. [VALUE] exceeded
limit of [LIMIT]*.
ADDITIONAL CAUSE/REMEDY
Check for wiring of current transformers to the ISM.
Check main circuit breaker for trip.
Check to be sure that the inlet guide vanes are closed
at start-up.
Check starter for proper operation.
Reduce unit pressure if possible.
Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.
Check motor current for proper calibration.
Check inlet guide vane actuator.
Check transformers to ISM.
Check power distribution bus.
Consult power company.
Check transformers to ISM.
Check distribution bus.
Consult power company.
Check transformers to ISM.
Check distribution bus.
Consult power company.
Check transformers to ISM.
Check distribution bus.
Consult power company.
Check ISM configuration.
Check ISM configuration.
Check ISM configuration.
*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
82
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS (cont)
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
OIL PRESS
SENSOR FAULT
ALARM MESSAGE
PRIMARY CAUSE
227->Oil Delta P [VALUE]
exceeded limit of
[LIMIT]*.
228
PROTECTIVE
LIMIT
LOW OI
PRESSURE
228->Oil Delta P [VALUE]
exceeded limit of
[LIMIT].*
229
PROTECTIVE
LIMIT
LOW CHILLED
WATER FLOW
229->Low Chilled Water
Flow; Check Delta P Config & Calibration
230
PROTECTIVE
LIMIT
LOW CONDENSER
WATER FLOW
230->Low Condenser
Water Flow; Check Delta
P Config & Calibration
231
PROTECTIVE
LIMIT
HIGH DISCHARGE
TEMP
231->Comp Discharge
Temp [VALUE] exceeded
limit of [LIMIT].*
232
PROTECTIVE
LIMIT
LOW REFRIGERANT
TEMP
232->Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
233
PROTECTIVE
LIMIT
HIGH MOTOR
TEMPERATURE
234
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
OIL LEVEL
SENSOR
HIGH CONDENSER
PRESSURE
233->Comp Motor Winding Temp [VALUE]
exceeded limit of
[LIMIT]*.
234->Check oil level in
separator.
235->Condenser Pressure [VALUE] exceeded
limit of [LIMIT]*.
236
PROTECTIVE
LIMIT
CCN OVERRIDE
STOP
236->CCN Override Stop
while in LOCAL run mode
237
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
SPARE SAFETY
DEVICE
EXCESSIVE
COMPR STALL
239
PROTECTIVE
LIMIT
TRANSDUCER
VOLTAGE FAULT
240
PROTECTIVE
LIMIT
LOW DISCHARGE
SUPERHEAT
241
LOSS OF
COMMUNICATION
LOSS OF
COMMUNICATION
POTENTIAL
FREEZE-UP
WITH STARTER
MODULE
WITH CCM
MODULE
EVAP PRESS/TEMP
TOO LOW
237->Spare Safety
Device
238->Compressor Stall:
Check condenser water
temp and flow
239->Transducer Voltage
Ref [VALUE] exceeded
limit of [LIMIT]*.
240->Check for Oil in
Refrigerant or Overcharge of Refrigerant
241->Loss of Communication With Starter.
242->Loss of Communication With CCM.
243->Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
244
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
245
PROTECTIVE
LIMIT
VFD SPEED
OUT OF RANGE
STATE
227
235
238
242
243
244->Condenser Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
245->Actual VFD Speed
[TARGET VFD] exceeded
limit of [SPEED ± 10%]*.
83
ADDITIONAL CAUSE/REMEDY
Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
Check transducer calibration.
Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
Check oil level.
Check for partially closed service valves.
Check oil filters.
Check for foaming oil at start-up.
Check transducer calibration.
Perform pump control test.
Check transducer accuracy and wiring.
Check water valves.
Check transducer calibration.
Perform pump control test.
Check transducer accuracy and wiring.
Check water valves.
Check transducer calibration.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper condenser flow and temperature.
Check for proper inlet guide vane and diffuser
actuator operation.
Check for fouled tubes or noncondensables in the
system.
Check for proper refrigerant charge.
Check float operation.
Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
Check motor sensors wiring and accuracy.
Check motor cooling line for proper operation, or
restrictions.
Check for excessive starts within a short time span.
Check for low oil level.
Check the oil level switch wiring and accuracy.
Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.
CCN has signaled the chiller to stop. Reset and
restart when ready. If the signal was sent by the
CVC, release the stop signal on the STATUS01
table.
Spare safety input has tripped or factory installed
jumper is not present.
Check condenser flow and temperatures.
Check stall protection configuration.
Check wiring to ISM.
Check wiring to CCM.
Check for proper refrigerant charge.
Check float operation.
Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS (cont)
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
DIRTY OIL FILTER
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
MOTOR ROTATION
INCORRECT
SPARE TEMPERATURE
#1
249
PROTECTIVE
LIMIT
SPARE TEMPERATURE
#2
250
PROTECTIVE
LIMIT
REFRIGERANT LEAK
SENSOR
251
PROTECTIVE
LIMIT
ISM CONFIG
CONFLICT
252
PROTECTIVE
LIMIT
ISM CONFIG
CONFLICT
253
FAILURE TO
START
CHECK REFRIGERANT
TYPE
STATE
246
247
248
ALARM MESSAGE
PRIMARY CAUSE
246->Oil Filter DELTA P
[VALUE] exceeded limit of
[LIMIT]. Check oil system.
247->Check motor wiring for
phase reversal.
248->Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT]*.
249->Spare Temperature #2
[VALUE] exceeded limit of
[LIMIT]*.
250->Refrigerant Leak Sensor
[VALUE] exceeded Limit of
[LIMIT].
251->ISM Config Conflict (ISM
Uploaded); Verify to Reset
Alarm
252->ISM Config Conflict (ISM
Downloading); Verify to Reset
Alarm
253->Startup Terminated.
Check Refrigerant Type.
ADDITIONAL CAUSE/REMEDY
*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
J. CHILLER ALERTS
140
PRIMARY
MESSAGE
SENSOR ALERT
SECONDARY
MESSAGE
LEAVING COND
WATER TEMP
141
SENSOR ALERT
ENTERING COND
WATER TEMP
142
LOW OIL PRESSURE
ALERT
CHECK OIL FILTER
143
AUTORESTART
PENDING
AUTORESTART
PENDING
LINE PHASE
LOSS
LINE VOLTAGE
DROP OUT
143->Line Phase Loss
145
AUTORESTART
PENDING
HIGH LINE
VOLTAGE
146
AUTORESTART
PENDING
LOW LINE
VOLTAGE
147
AUTORESTART
PENDING
STARTER MODULE
RESET
148
AUTORESTART
PENDING
SENSOR ALERT
POWER LOSS
145>Line Overvoltage —
Average Line Volt
[VALUE]
146->Line Undervoltage
— Average Line Volt
[VALUE]
147->Starter Module
Power-On Reset When
Running
148->Control Power-Loss
When Running
149->Comp Discharge
Temp [VALUE] exceeded
limit of [LIMIT]*.
STATE
144
149
HIGH DISCHARGE
TEMP
ALARM MESSAGE
PRIMARY CAUSE
140->Sensor Fault:
Check Leaving Cond
Water Sensor
141->Sensor Fault:
Check Entering Cond
Water Sensor
142->Low Oil Pressure
Alert. Check Oil Filter.
144->Single Cycle Line
Voltage Dropout
84
ADDITIONAL CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for partially or closed shut-off valves.
Check oil filter.
Check oil level.
Check transducer wiring and accuracy.
Power loss has been detected in any phase.
Chiller automatically restarting.
A drop in line voltage has been detected within
2 voltage cycles. Chiller automatically restarting
if restart is enabled.
Check line power.
Check line power.
ISM has detected a hardware fault and has
reset. Chiller automatically restarting.
Check control power.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper condenser flow and
temperature.
Check for high lift or low load.
Check for proper slide valve operation.
Check for fouled tubes or noncondensables in
the refrigerant system.
Table 9 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
151
PRIMARY
MESSAGE
CONDENSER
PRESSURE
ALERT
SECONDARY
MESSAGE
PUMP RELAY
ENERGIZED
ALARM MESSAGE
PRIMARY CAUSE
151->High Condenser
Pressure [VALUE]: Pump
Energized to Reduce
Pressure.
152
RECYCLE
ALERT
EXCESSIVE RECYCLE
STARTS
152->Excessive recycle starts.
153
no message:
ALERT only
no message;
ALERT only
154
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
153->Lead/Lag Disabled:
Duplicate Chiller Address;
Check Configuration
154->Condenser freeze up
prevention
155
OPTION SENSOR
FAULT
REMOTE RESET
SENSOR
156
OPTION SENSOR
FAULT
OPTION SENSOR
FAULT
AUTO CHILLED
WATER RESET
AUTO DEMAND
LIMIT INPUT
158
SENSOR ALERT
SPARE TEMPERATURE
#1
159
SENSOR ALERT
SPARE TEMPERATURE
#2
160
MACHINE ALERT
DIRTY OIL FILTER
STATE
157
155->Sensor Fault/Option
Disabled:
Remote Reset Sensor
156->Sensor Fault/Option Disabled:Auto Chilled Water Reset
157->Sensor Fault/Option
Disabled:
Auto Demand Limit Input
158->Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT].*
159->Spare Temperature #2
[VALUE] exceeded limit of
[LIMIT].*
160->Oil Filter Delta P [VALUE]
exceeds limit of [LIMIT]. Check
oil solenoid and filter.
ADDITIONAL CAUSE/REMEDY
Check sensor wiring and accuracy.
Check condenser flow and fluid
temperature.
Check for fouled tubes. This alarm is not
caused by the High Pressure Switch.
Chiller load is too low to keep compressor
on line and there has been more than
5 starts in 4 hours. Increase chiller load,
adjust hot gas bypass, increase RECYCLE
RESTART DELTA T from SETUP1 Screen.
Illegal chiller address configuration in Lead/
Lag screen. Both chillers require a different
address.
The condenser pressure transducer is
reading a pressure that could freeze the
condenser tubes.
Check for condenser refrigerant leaks.
Check fluid temperature.
Check sensor wiring and accuracy.
Place the chiller in PUMPDOWN mode if
the vessel is evacuated.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor(s).
Check filter.
*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
85
Table 10A — Thermistor Temperature (F) vs Resistance/VoltageDrop
TEMPERATURE
(F)
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
VOLTAGE RESISTANCE
DROP (V)
(Ohms)
4.821
98,010
4.818
94,707
4.814
91,522
4.806
88,449
4.800
85,486
4.793
82,627
4.786
79,871
4.779
77,212
4.772
74,648
4.764
72,175
4.757
69,790
4.749
67,490
4.740
65,272
4.734
63,133
4.724
61,070
4.715
59,081
4.705
57,162
4.696
55,311
4.688
53,526
4.676
51,804
4.666
50,143
4.657
48,541
4.648
46,996
4.636
45,505
4.624
44,066
4.613
42,679
4.602
41,339
4.592
40,047
4.579
38,800
4.567
37,596
4.554
36,435
4.540
35,313
4.527
34,231
4.514
33,185
4.501
32,176
4.487
31,202
4.472
30,260
4.457
29,351
4.442
28,473
4.427
27,624
4.413
26,804
4.397
26,011
4.381
25,245
4.366
24,505
4.348
23,789
4.330
23,096
4.313
22,427
4.295
21,779
4.278
21,153
4.258
20,547
4.241
19,960
4.223
19,393
4.202
18,843
4.184
18,311
4.165
17,796
4.145
17,297
4.125
16,814
4.103
16,346
4.082
15,892
4.059
15,453
4.037
15,027
4.017
14,614
3.994
14,214
3.968
13,826
3.948
13,449
3.927
13,084
3.902
12,730
3.878
12,387
3.854
12,053
3.828
11,730
3.805
11,416
3.781
11,112
3.757
10,816
3.729
10,529
3.705
10,250
3.679
9,979
3.653
9,717
3.627
9,461
3.600
9,213
3.575
8,973
3.547
8,739
3.520
8,511
3.493
8,291
3.464
8,076
3.437
7,868
TEMPERATURE
(F)
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
VOLTAGE RESISTANCE
DROP (V)
(Ohms)
3.409
7,665
3.382
7,468
3.353
7,277
3.323
7,091
3.295
6,911
3.267
6,735
3.238
6,564
3.210
6,399
3.181
6,238
3.152
6,081
3.123
5,929
3.093
5,781
3.064
5,637
3.034
5,497
3.005
5,361
2.977
5,229
2.947
5,101
2.917
4,976
2.884
4,855
2.857
4,737
2.827
4,622
2.797
4,511
2.766
4,403
2.738
4,298
2.708
4,196
2.679
4,096
2.650
4,000
2.622
3,906
2.593
3,814
2.563
3,726
2.533
3,640
2.505
3,556
2.476
3,474
2.447
3,395
2.417
3,318
2.388
3,243
2.360
3,170
2.332
3,099
2.305
3,031
2.277
2,964
2.251
2,898
2.217
2,835
2.189
2,773
2.162
2,713
2.136
2,655
2.107
2,597
2.080
2,542
2.053
2,488
2.028
2,436
2.001
2,385
1.973
2,335
1.946
2,286
1.919
2,239
1.897
2,192
1.870
2,147
1.846
2,103
1.822
2,060
1.792
2,018
1.771
1,977
1.748
1,937
1.724
1,898
1.702
1,860
1.676
1,822
1.653
1,786
1.630
1,750
1.607
1,715
1.585
1,680
1.562
1,647
1.538
1,614
1.517
1,582
1.496
1,550
1.474
1,519
1.453
1,489
1.431
1,459
1.408
1,430
1.389
1,401
1.369
1,373
1.348
1,345
1.327
1,318
1.308
1,291
1.291
1,265
1.289
1,240
1.269
1,214
1.250
1,190
1.230
1,165
86
TEMPERATURE
(F)
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
VOLTAGE RESISTANCE
DROP (V)
(Ohms)
1.211
1,141
1.192
1,118
1.173
1,095
1.155
1,072
1.136
1,050
1.118
1,029
1.100
1,007
1.082
986
1.064
965
1.047
945
1.029
925
1.012
906
0.995
887
0.978
868
0.962
850
0.945
832
0.929
815
0.914
798
0.898
782
0.883
765
0.868
750
0.853
734
0.838
719
0.824
705
0.810
690
0.797
677
0.783
663
0.770
650
0.758
638
0.745
626
0.734
614
0.722
602
0.710
591
0.700
581
0.689
570
0.678
561
0.668
551
0.659
542
0.649
533
0.640
524
0.632
516
0.623
508
0.615
501
0.607
494
0.600
487
0.592
480
0.585
473
0.579
467
0.572
461
0.566
456
0.560
450
0.554
445
0.548
439
0.542
434
0.537
429
0.531
424
0.526
419
0.520
415
0.515
410
0.510
405
0.505
401
0.499
396
0.494
391
0.488
386
0.483
382
0.477
377
0.471
372
0.465
367
0.459
361
0.453
356
0.446
350
0.439
344
0.432
338
0.425
332
0.417
325
0.409
318
0.401
311
0.393
304
0.384
297
0.375
289
0.366
282
Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE
(C)
–40
–39
–38
–37
–36
–35
–34
–33
–32
–31
–30
–29
–28
–27
–26
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
VOLTAGE
DROP (V)
4.896
4.889
4.882
4.874
4.866
4.857
4.848
4.838
4.828
4.817
4.806
4.794
4.782
4.769
4.755
4.740
4.725
4.710
4.693
4.676
4.657
4.639
4.619
4.598
4.577
4.554
4.531
4.507
4.482
4.456
4.428
4.400
4.371
4.341
4.310
4.278
4.245
4.211
4.176
4.140
4.103
4.065
4.026
3.986
3.945
3.903
3.860
3.816
3.771
3.726
3.680
3.633
3.585
3.537
3.487
3.438
3.387
3.337
3.285
3.234
3.181
3.129
3.076
3.023
2.970
2.917
2.864
2.810
2.757
2.704
2.651
2.598
2.545
2.493
2.441
2.389
2.337
2.286
2.236
2.186
2.137
2.087
2.039
1.991
1.944
RESISTANCE
(Ohms)
168 230
157 440
147 410
138 090
129 410
121 330
113 810
106 880
100 260
94 165
88 480
83 170
78 125
73 580
69 250
65 205
61 420
57 875
54 555
51 450
48 536
45 807
43 247
40 845
38 592
38 476
34 489
32 621
30 866
29 216
27 633
26 202
24 827
23 532
22 313
21 163
20 079
19 058
18 094
17 184
16 325
15 515
14 749
14 026
13 342
12 696
12 085
11 506
10 959
10 441
9 949
9 485
9 044
8 627
8 231
7 855
7 499
7 161
6 840
6 536
6 246
5 971
5 710
5 461
5 225
5 000
4 786
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363
2 272
TEMPERATURE
(C)
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
87
VOLTAGE
DROP (V)
1.898
1.852
1.807
1.763
1.719
1.677
1.635
1.594
1.553
1.513
1.474
1.436
1.399
1.363
1.327
1.291
1.258
1.225
1.192
1.160
1.129
1.099
1.069
1.040
1.012
0.984
0.949
0.920
0.892
0.865
0.838
0.813
0.789
0.765
0.743
0.722
0.702
0.683
0.665
0.648
0.632
0.617
0.603
0.590
0.577
0.566
0.555
0.545
0.535
0.525
0.515
0.506
0.496
0.486
0.476
0.466
0.454
0.442
0.429
0.416
0.401
0.386
0.370
RESISTANCE
(Ohms)
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 118
1 079
1 041
1 006
971
938
906
876
836
805
775
747
719
693
669
645
623
602
583
564
547
531
516
502
489
477
466
456
446
436
427
419
410
402
393
385
376
367
357
346
335
324
312
299
285
Control Modules — Turn controller power off before
Notes on Module Operation
servicing controls. This ensures safety and prevents damage to
the controller.
The CVC, CCM, and ISM modules perform continuous diagnostic evaluations of the hardware to determine its condition.
Proper operation of all modules is indicated by LEDs (lightemitting diodes) located on the circuit board of the CVC,
CCM, and ISM.
There is one green LED located on the CCM and ISM
boards respectively, and one red LED located on the CVC,
CCM, and ISM boards respectively.
RED LED (Labeled as STAT) — If the red LED:
• blinks continuously at a 2-second interval, the module is
operating properly
• is lit continuously, there is a problem that requires
replacing the module
• is off continuously, the power should be checked
• blinks 3 times per second, a software error has been discovered and the module must be replaced
If there is no input power, check the fuses and circuit breaker. If the fuse is good, check for a shorted secondary of the
transformer or, if power is present to the module, replace the
module.
GREEN LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the controller and the network modules and should blink continuously.
J5
KEYPAD
J1
POWER/CCN
1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and
the CVC. Communications between the CVC and the
CCM is accomplished through the SIO (Sensor Input/
Output) bus, which is a phone cable. The communication between the CCM and ISM is accomplished
through the sensor bus, which is a 3-wire cable.
2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red
LED operation. If the red LED is normal, check the
module address switches (Fig. 42-44).
All system operating intelligence resides in the CVC.
Some safety shutdown logic resides in the ISM in case
communications are lost between the ISM and CVC.
Outputs are controlled by the CCM and ISM as well.
3. Power is supplied to the modules within the control
panel via 24-vac power sources.
The transformers are located within the power panel,
with the exception of the ISM, which operates from a
115-vac power source and has its own 24-vac transformer located in the module.
In the power panel, T1 supplies power to the compressor oil heater, oil pump, and optional hot gas bypass,
and T2 supplies power to both the CVC and CCM.
Power is connected to Plug J1 on each module.
MODULE PART #
SOFTWARE PART #
J7
SIO
STAT
CONTRAST
BACK OF CVC
(CHILLER VISUAL
CONTROLLER)
J8
SERVICE
Fig. 42 — Rear of CVC (Chiller Visual Controller)
88
Chiller Control Module (CCM) (Fig. 43)
8. Access the MAINSTAT table and highlight the TOTAL
COMPRESSOR STARTS parameter. Press the
SELECT softkey. Increase or decrease the value to
match the starts value recorded in Step 3. Press the
ENTER softkey when you reach the correct value.
Now, move the highlight bar to the COMPRESSOR
ONTIME parameter. Press the SELECT softkey.
Increase or decrease the run hours value to match the
value recorded in Step 2. Press the ENTER softkey
when the correct value is reached.
INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
numbers for your application.
OUTPUTS — Output is 24 vac. There are 2 terminals per output. Refer to the chiller wiring diagram for your specific application for the correct terminal numbers.
Integrated Starter Module (ISM) (Fig. 44)
INPUTS — Inputs on strips J3-5 and J3 are analog and discrete (on/off) inputs. The specific application of the chiller determines which terminals are used. Refer to the individual
chiller wiring diagram for the correct terminal numbers for
your application.
OUTPUTS — Outputs are 24 vac and wired to strip J9. There
are 2 terminals per output.
9. Complete the CVC installation. Following the instructions in the Input Service Configurations section,
page 60, input all the proper configurations such as the
time, date, etc. Check the pressure transducer calibrations. PSIO installation is now complete.
Replacing Defective Processor Modules —
Solid-State Starters — Troubleshooting information
pertaining to the Benshaw, Inc., solid-state starter may be
found in the following paragraphs and in the Carrier
REDISTART MICRO Instruction Manual supplied by the
starter vendor.
Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables found
in the Benshaw manual.
The module replacement part number is printed on a small
label on the rear of the CVC module. The chiller model and
serial numbers are printed on the chiller nameplate located on
an exterior corner post. The proper software is factory-installed
by Carrier in the replacement module. When ordering a
replacement chiller visual controller (CVC) module, specify
the complete replacement part number, full chiller model number, and chiller serial number. The installer must configure the
new module to the original chiller data. Follow the procedures
described in the Software Configuration section on page 60.
1. Motor terminals or starter output lugs or wire should not
be touched without disconnecting the incoming power
supply. The silicon control rectifiers (SCRs) although
technically turned off still have AC mains potential on
the output of the starter.
2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the unit
is off.
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
INSTALLATION
1. Verify the existing CVC module is defective by using
the procedure described in the Troubleshooting Guide
section, page 76, and the Control Modules section,
page 88. Do not select the ATTACH TO NETWORK
DEVICE table if the CVC indicates a communication
failure.
2. Data regarding the CVC configuration should have
been recorded and saved. This data must be reconfigured into the new CVC. If this data is not available,
follow the procedures described in the Software Configuration section.
If a CCN Building Supervisor or Service Tool is available, the module configuration should have already
been uploaded into memory. When the new module is
installed, the configuration can be downloaded from
the computer.
Any communication wires from other chillers or CCN
modules should be disconnected to prevent the new
CVC module from uploading incorrect run hours into
memory.
3. To install this module, record values for the TOTAL
COMPRESSOR STARTS and the COMPRESSOR
ONTIME from the MAINSTAT screen on the CVC.
4. Power off the controls.
5. Remove the old CVC.
6. Install the new CVC module. Turn the control power
back on.
7. The CVC now automatically attaches to the local network device.
With power off:
• Inspect for physical damage and signs of arcing, overheating, etc.
• Verify the wiring to the starter is correct.
• Verify all connections in the starter are tight.
• Check the control transformer fuses.
TESTING SILICON CONTROL RECTIFIERS IN THEBENSHAW, INC., SOLID-STATE STARTERS — If an
SCR is suspected of being defective, use the following procedure as part of a general troubleshooting guide.
1. Verify power is applied.
2. Verify the state of each SCR light-emitting diode
(LED) on the micropower card.
NOTE: All LEDs should be lit. If any red or green side
of these LEDs is not lit, the line voltage is not present
or one or more SCRs has failed.
3. Check incoming power. If voltage is not present check
the incoming line. If voltage is present, proceed to
Steps 4 through 11.
NOTE: If after completing Steps 4 - 11 all measurements are within specified limits, the SCRs are functioning normally. If after completing Steps 4 - 11
resistance measurements are outside the specified
limits, the motor leads on the starter power lugs T1
through T6 should be removed and the steps repeated.
This will identify if abnormal resistance measurements
are being influenced by the motor windings.
4. Remove power from the starter unit.
89
J11
DISCRETE
OUTPUTS
J12
DISCRETE
OUTPUTS
J1
24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2
V/I INPUTS
J5
STAT
COMM
THERMISTORS
J4
PRESSURE
J2
DIFF PRESSURE
J3
Fig. 43 — Chiller Control Module (CCM)
J9
J8
J7
COM STAT
INTEGRATEDSTARTERMODULE
J1
FUSE
J2
J3-1
J3-2
J3-3
Fig. 44 — Integrated Starter Module (ISM)
90
J4
J5
J6
5. Using quarter-turn increments, alternating between
clamping bolts, apply the appropriate number of whole
turns referencing the table in Fig. 45.
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
MEASURE
BETWEEN
T1 and T6
T2 and T4
T3 and T5
6.
7.
8.
9.
10.
SCR PAIRS
BEING
CHECKED
3 and 6
2 and 5
1 and 4
RECORDED
VALUE
Care must be taken to prevent nut rotation while tightening
the bolts. If the nut rotates while tightening the bolt, SCR
replacement must be started over.
If all measured values are greater than 5K ohms, proceed to Step 10. If any values are less than 5K ohms,
one or more of the SCRs in that pair is shorted.
Remove both SCRs in the pair (See SCR Removal/
Installation).
Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically,
only one is shorted. If both SCRs provide acceptable
resistance measurements, proceed to Step 10.
Replace the defective SCR(s).
Retest the “pair” for resistance values indicated above.
On the right side of the firing card, measure the resistance
between the red and white gate/cathode leads for each
SCR (1 through 6). A measurement between 5 and
50 ohms is normal. Abnormally high values may indicate
a failed gate for that SCR.
6. Reconnect the red (cathode) wire from the SCR and
the white (anode-gate) wire to the appropriate location
on the firing card (i.e., SCR1 wires to firing card terminal G1-white wire, and K1-red wire).
7. Reconnect all other wiring and bus work.
8. Return starter to normal operation.
NUT
CLAMPING
BOLT
A
ALUMINUM
HEATSINK
LOOSEN
AND
TIGHTEN
BOLTS
FROM
THIS END
ROLL PIN
If any red or white SCR gate leads are removed from the
firing card or an SCR, care must be taken to ensure the
leads are replaced EXACTLY as they were (white wires to
gates, and red wires to cathodes on both the firing card and
SCR), or damage to the starter and/or motor may result.
SCR
11. Replace the SCRs and retest the pair.
SCR REMOVAL/INSTALLATION — Refer to Fig. 45.
1. Remove the SCR by loosening the clamping bolts on
each side of the SCR,
2. After the SCR has been removed and the bus work is
loose, apply a thin coat of either silicon based thermal
joint compound or a joint compound for aluminum or
copper wire connections to the contact surfaces of the
replacement SCR. This allows for improved heat dissipation and electrical conductivity.
3. Place the SCR between the roll pins on the heatsink
assemblies so the roll pins fit into the small holes in
each side of the SCR.
NOTE: Ensure the SCR is installed so the cathode side
is the side from which the red wire extends. The heatsink is labeled to show the correct orientation.
4. Hand tighten the bolts until the SCR contacts the heat
sink.
SCR PART
NUMBER
BISCR
CLAMP
SIZE
6601218
1030
6601818
1030
8801230
1035
8801830
1035
15001850
2040
15001850
2050
220012100
330018500
A
BOLT
NO. OF
DIMENSION
LENGTH
TURNS
(in.)
(in.)
2.75
3.0
11/2
(70 mm)
(76 mm)
2.75
3.0
11/2
(70 mm)
(76 mm)
2.75
3.5
13/4
(70 mm)
(89 mm)
2.75
3.0
13/4
(70 mm)
(89 mm)
4.00
4.0
23/4
(102 mm)
(102 mm)
4.00
5.0
23/4
(102 mm)
(127 mm)
Consult Benshaw Representative
Consult Benshaw Representative
Fig. 45 — SCR Installation
91
Physical Data — For operator convenience during troubleshooting, additional details regarding compressor torque
specifications, physical data, electrical data, and wiring schematics may be found in Tables 11-18 and Fig. 46-52.
Table 11 — 23XL Heat Exchanger Weights
Dry Wt (lb)*
SIZE
10
11
20
21
40
41
42
43
Cooler Cond
Only† Only
2480
2650
2845
3000
5030
5180
5345
5525
2890
3020
3250
3445
4690
4835
5005
5185
ENGLISH
SI
Machine Charge
Dry Wt (kg)*
Machine Charge
Refrigerant (lb)
Water (gal)
Refrigerant (kg)
Cooler Cond
Economizer
No Economizer
Economizer
No Economizer
Cooler Cond Only† Only
HCFC-22 HFC-134a HCFC-22 HFC-134a
HCFC-22 HFC-134a HCFC-22 HFC-134
650
**
600
**
34
39.2
1125 1310
295
**
272
**
650
**
600
**
4
44.4
1202 1370
295
**
272
**
750
**
700
**
45
49.2
1291 1474
340
**
318
**
750
**
700
**
49
56.4
1361 1156
340
**
318
**
1000
850
900
800
49.2
51.6
2282 2127
454
386
408
363
1100
900
1000
850
54
57
2350 2193
499
408
454
386
1200
950
1100
900
60
63
2424 2270
544
431
499
408
1300
1000
1200
950
66
70
2506 2352
590
454
544
431
LEGEND
NIH — Nozzle-In-Head
*Weight based on: 035 in. wall copper Turbo-B2 tubes in cooler, Turbo chill in condenser.
2-pass, 150 psi NIH waterbox arrangements (sizes 10, 11, 20, 21)
3-pass, 300 psi NIH waterbox arrangements (sizes 40, 41, 42, 43)
†Weight of optional economizer is not included and must be added to cooler weight.
**Not available.
NOTE: Standard shipment is with refrigerant charged, so be sure to add refrigerant charge to dry weight.
Table 12 — 23XL Compressor Weights
23XL
UNIT
COMPRESSOR SIZE (Tons)
C2
C4
C6
D4
D6
TC Frame 1
TC Frame 2
TD Frame 4
ASSEMBLY
lb
kg
2270
1029
2300
1043
2400
1088
3300
1497
3400
1542
Table 13 — 23XL Component Weights
COMPONENT
Oil Separator
Economizer†
Muffler
Discharge Piping:
Pipe
Isolation Valve†
Adaptor Flange
Power Panel
Starter†
Control Center
FRAME 1 AND 2
lb
kg
1180
535
296
134
170
77
44
30
76
20
500
31
20
14
34
9
227
14
*The TD frame 4 muffler is included in the oil separator weight.
†Optional.
92
FRAME 4
lb
2880*
560
*
kg
1306*
254
*
30
76
20
500
31
14
34
9
227
14
Water (L)
Cooler Cond
130
152
170
186
186
204
227
250
105
168
186
214
195
216
239
264
Table 14A — 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)*
HEAT
EXCHANGER
COOLER OR
CONDENSER
WATERBOX
DESCRIPTION
NIH, 1 Pass
PSI
(kPa)
NIH, 2 Pass (Plain)
150
(1034)
NIH, 2 Pass (With Pipe Nozzles)
FRAME 1
150
(1034)
NIH, 3 Pass
FRAME 2
lbs
118
kg
54
lbs
128
kg
58
100
46
148
67
185
84
200
91
166
76
180
82
LEGEND
NIH — Nozzle-In-Head
*These weights are given for reference only. They have been included in heat exchanger weights
shown in Table 4.
NOTE: Add 30 lb (14 Kg) for bolts.
Table 14B — 23XL Waterbox Cover Weight (Frame 4 Machines)*
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
NIH, 1 Pass Cover
COOLER
CONDENSER
ENGLISH (lb)
Frame 4,
Frame 4,
Std Nozzles
Flanged
150 psig 300 psig 150 psig 300 psig
284
414
324
491
SI (kg)
Frame 4,
Frame 4,
Std Nozzles
Flanged
1034 kPa 2068 kPa 1034 kPa 2068 kPa
129
188
147
223
NIH, 2 Pass Cover
285
411
341
523
129
187
155
237
NIH, 3 Pass Cover
292
433
309
469
133
197
140
213
NIH, Plain End Cover
243
292
243
292
110
133
110
133
MWB Cover
CS
621
CS
621
CS
282
CS
282
Plain End Cover
CS
482
CS
482
CS
219
CS
219
NIH, 1 Pass Cover
306
446
346
523
139
202
157
237
NIH, 2 Pass Cover
288
435
344
547
131
197
156
248
NIH, 3 Pass Cover
319
466
336
502
145
212
153
228
NIH, Plain End Cover
226
271
226
271
103
123
103
123
MWB Cover
CS
474
CS
474
CS
215
CS
215
Plain End Cover
CS
359
CS
359
CS
163
CS
163
LEGEND
— Contact Syracuse
CS
MWB — Marine Waterbox
NIH — Nozzle-In-Head
*These weights are given for reference only. The 150 psig (1034 kPa) standard waterbox cover
weights have been included in the heat exchanger weights shown in Table 11.
93
Table 15 — Optional Storage Tank and/or Pumpout System Physical Data
UNIT
SIZE
28
52
TANK OUTSIDE
DIAMETER
in.
24.00
27.25
DRY WEIGHT
mm
610
692
lb
2200
3270
kg
998
1606
MAXIMUM REFRIGERANT CAPACITY
ASHRAE/ANSI 15
ARI 495
HCFC-22
HFC-134a
HCFC-22
HFC-134a
lb
kg
lb
kg
lb
kg
lb
kg
1840
835
1865
845
1645
747
1665
755
3525
1599
3570
1619
3155
1431
3195
1449
LEGEND
— American National Standards Institute
ANSI
— Air Conditioning and Refrigeration Institute
ARI
ASHRAE — American Society of Heating, Refrigeration,
and Air Conditioning Engineers
NOTES:
1. ANSI/ASHRAE 15 — Safety Code for Mechanical Refrigeration
2. Dry weights include the pumpout condensing unit weight of 210 lbs (95 kg).
Table 16 — Optional Storage Tank and/or
Pumpout System Electrical Data
MOTOR CODE
1
4
5
6
CONDENSER UNIT
19EA47-748
19EA42-748
19EA44-748
19EA46-748
VOLTS-PH-HZ
575-3-60
200/208-3-60
230-3-60
400/460-3-50/60
MAX RLA
3.8
10.9
9.5
4.7
LRA
23.0
63.5
57.5
28.8
LEGEND
LRA — Locked Rotor Amps
RLA — Rated Load Amps
Table 17A — 23XL Waterbox Cover Weights (TC Frame 1 and 2 Chillers)*
HEAT
EXCHANGER
Cooler or
Condenser
WATERBOX
DESCRIPTION
NIH, 1 Pass
NIH, 2 Pass (Plain)
NIH, 2 Pass (With Pipe Nozzles)
NIH, 3 Pass
FRAME 1
PSI
(kPa)
150
(1034)
150
(1034)
FRAME 2
lbs
118
100
185
kg
54
46
84
lbs
128
148
200
kg
58
67
91
166
76
180
82
LEGEND
NIH — Nozzle-In-Head
*These weights are given for reference only. They have been included in heat exchanger weights shown in Table 11.
NOTE: Add 30 lb (14 Kg) for bolts.
Table 17B — 23XL Waterbox Cover Weight (TD Frame 4 Chillers)*
HEAT
EXCHANGER
COOLER
CONDENSER
CS
MWB
NIH
WATERBOX
DESCRIPTION
NIH, 1 Pass Cover
NIH, 2 Pass Cover
NIH, 3 Pass Cover
NIH, Plain End Cover
MWB Cover
Plain End Cover
NIH, 1 Pass Cover
NIH, 2 Pass Cover
NIH, 3 Pass Cover
NIH, Plain End Cover
MWB Cover
Plain End Cover
ENGLISH (lb)
Frame 4,
Frame 4,
Std Nozzles
Flanged
150 psig 300 psig 150 psig 300 psig
284
414
324
491
285
411
341
523
292
433
309
469
243
292
243
292
CS
621
CS
621
CS
482
CS
482
306
446
346
523
288
435
344
547
319
466
336
502
226
271
226
271
CS
474
CS
474
CS
359
CS
359
LEGEND
— Contact Syracuse
— Marine Waterbox
— Nozzle-In-Head
*These weights are given for reference only. The 150 psig (1034 kPa) standard waterbox
cover weights have been included in the heat exchanger weights shown in Table 11.
94
SI (kg)
Frame 4,
Frame 4,
Std Nozzles
Flanged
1034 kPa 2068 kPa 1034 kPa 2068 kPa
129
188
147
223
129
187
155
237
133
197
140
213
110
133
110
133
CS
282
CS
282
CS
219
CS
219
139
202
157
237
131
197
156
248
145
212
153
228
103
123
103
123
CS
215
CS
215
CS
163
CS
163
Table 18 — 23XL Compressor Torque Specification Chart for Metric amd American Fasteners
ITEM
CAP SCREW
SIZE AND TYPE
GRADE
1.
2.
1.
2.
M5 X 0.8 X 12 S.H.
M6 X 1 X 16 S.H.
M10 X 1.5 X 35 H.H.
M10 X 1.5 X 40 S.H.
M10 X 1.5 X 50 H.H.
M12 X 1.75 X 40 S.H.
M12 X 1.75 X 50 S.H.
CAP SCREW
10.9
M12 X 1.75 X 60 S.H.
M12 X 1.75 X 70 S.H.
M12 X 1.75 X 80 S.H.
M12 X 1.75 X 90 S.H.
FRAME 1 AND 2
M16 X 2 X 55 S.H.
FRAME 4
M16 X 2 X 70 S.H.
M20 X 2.5 X 70 S.H.
M22 X 2.5 X 80 S.H.
SET SCREW
M10 X 1.5 X 16 S.S.
10.9
M10 X 1.5 X 30 S.S.
1/8 NPTF
PIPE PLUG
1/
4
NPTF
N/A
7/ -20
16
9/16 -18
HEX PLUG
3/ -16
4
N/A
11/16-12
13/16-12
5/8-11
TERMINAL PIN
N/A
13/16-12
RELIEF VALVE
M20 X 1
M35 X 1.5
15/8 -12 UN-2A
N/A
PLUG, ORIFICE
M8 X 1.25
N/A
WAFER HEAD SCREW
M6 X 1
N/A
LOCKNUT
ASSEMBLY LOCATION
N/A
FUSITE-MOTOR CASING
SLIDE SEAL RETAINER-CYLINDER STOP
CONTROL VALVES-SLIDE CASING
SLIDE SEAL ADAPTOR-SEPARATOR PLATE
(FRAME 1 AND 2 ONLY)
3. SLIDE SEAL ADAPTOR-SLIDE CASING PLUG
(FRAME 4 ONLY)
1. BRG RETAINER-MALE ROTOR
2. BRG RETAINER-FEMALE ROTOR
1. SLIDE VALVE COVER-SLIDE CASING
2. SLIDE CASING-SEPARATOR PLATE (TC FRAME 1
AND 2 ONLY)
MOTOR ROTOR-MALE ROTOR
SERVICE VALVE PAD-MOTOR COVER
TC FRAME 1 AND 2 ONLY
1. MOTOR COVER-MOTOR CASING
2. SEPARATOR PLATE-OUTLET CASING
3. DISCHARGE COVER-OUTLET CASING
1. MOTOR END PLATE-MOTOR COVER-MOTOR CASING (FRAME 1 AND 2 ONLY)
2. MOTOR COVER-MOTOR CASING (TD FRAME 4
ONLY)
3. SLIDE CASING-OUTLET CASING (TD FRAME 4
ONLY)
TD FRAME 4 ONLY
MOTOR END PLATE-MOTOR COVER-MOTOR CASING
TC FRAME 1 AND 2 ONLY
SLIDE CASING-SEPARATOR PLATE-OUTLET CASING
TD FRAME 4 ONLY
SLIDE CASING (BOTTOM)-OUTLET CASING
1. ROTOR CASING-INLET CASING AND OUTLET
CASING
2. MOTOR CASING-INLET CASING
3. OPEN DRIVE END COVER-INLET CASING
4. DISCHARGE COVER-OUTLET CASING
(TD FRAME 4 ONLY)
INLET FLANGES-INLET CASING (TC FRAME 1 AND 2
ONLY)
TD FRAME 4 ONLY
INLET FLANGES-INLET CASING
TD FRAME 4 ONLY
OPEN DRIVE SEAL ADAPTER
STATOR KEY LOCK
INLET CASING
TD FRAME 4 ONLY
SLIDE CASING
1. INLET CASING
2. SLIDE CASING
1. MOTOR CASING
2. OUTLET CASING
3. ROTOR CASING
4. SLIDE CASING
1. OUTLET CASING
2. SLIDE CASING (TC FRAME 1 AND 2 ONLY)
1. INLET CASING
2. ROTOR CASING
3. OUTLET CASING
TD FRAME 4
OUTLET CASING
1. TERMINAL NUTS
2. MOTOR LEAD
1. TERMINAL PIN BODY
2. MOTOR CASING
SLIDE VALVE ASSEMBLY
SLIDE VALVE ASSEMBLY
ROTOR CASING
1. INLET CASING
2. OPEN DRIVE END COVER (TC FRAME 1 AND 2
ONLY)
TD FRAME 4 ONLY
SLIDE VALVE ASSEMBLY
95
Nm
TORQUE
Lb-Ft
Lb-in.
4.1-5.4
3-4
36-48
6.8-9.6
5-7
60-84
41-47
30-35
N/A
61-68
45-50
N/A
20-27
103-115
15-20
75-85
N/A
N/A
103-115
75-85
N/A
252-280
185-205
N/A
485-513
355-375
N/A
697-724
510-530
N/A
41-47
30-35
N/A
13-20
20-27
10-15
15-20
120-180
180-240
27-34
20-25
240-300
13-16
10-12
130-140
23-26
17-19
210-230
60-65
44-48
530-570
112-125
83-92
1000-1100
125-140
92-103
1100-1240
23-26
17-19
N/A
27-34
20-25
N/A
68-75
95-102
345-379
50-55
70-75
254-279
N/A
N/A
N/A
19-24
14-18
168-216
13-15
10-11
120-130
96
CB
CCM
CVC
COMPR
COND
DL/DP
DISCH
ENT
—
—
—
—
—
—
—
—
Circuit Breaker
Chiller Control Module
Chiller Visual Controller
Compressor
Cond
Datalink or Dataport
Discharge
Entering
EVAP
EXT
GND
HGBP
ISM
LVG
PRESS
REQMT
—
—
—
—
—
—
—
—
**
SW
TEMP
TB
VVI
—
—
—
—
Denotes Motor Starter Panel Conn.
Switch
Temperature
Terminal Board
Variable Volume Index
Denotes Power Panel Terminal
Fig. 46 — 23XL Chiller Control Schematic
Evaporator
External
Ground
Hot Gas Bypass
Integrated Starter Module
Leaving
Pressure
Requirement
LEGEND
Denotes Component Terminal
Wire Splice
Denotes Conductor
Male/Female Connector
Option Wiring
97
CB
CCM
HGBP
ISM
TB
VVI
—
—
—
—
—
—
*
**
Denotes Component Terminal
Wire Splice
Option Wiring
Denotes Conductor Male/Female Conn.
Denotes Control Panel Conn.
Denotes Motor Starter Panel Conn.
Fig. 47 — Power Panel Wiring Schematic
Circuit Breaker
Chiller Control Module
Hot Gas Bypass
Integrated Starter Module
Terminal Board
Variable Volume Index
Denotes Power Panel Terminal
LEGEND
NOTE: Power factor correction capacitors (when required) are
connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130.
LEGEND
AUX
C
CB
CT
DS
FU
G
HPR
—
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Current Transformer
Disconnect Switch
Fuse
Ground
High-Pressure Relay
ISM
L
LL
M
RES
S
TB
—
—
—
—
—
—
—
Integrated Starter Module
Main Supply Power
Control Power Supply
Contactor
Resistor
Contactor
Terminal Block
Yellow wires remain energized when unit main disconnect is off. Optional
features are indicated by bold dashed lines.
.
Dry Contact
Field Connection
--------------For connection diagram refer to 261143 D4.
Fig. 48 — Cutler-Hammer Wye Delta Unit Mounted Starter Wiring Schematic (Low Voltage)
98
99
Fig. 49 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
100
AUX
BR
CB
COMM
COND
CPU
CVC
CT
EVAP
FU
G
L
LL
M
O/L
S
SCR
ST
TB
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Field Wiring
Shield Wire
Twisted Shielded Pair
Twisted Pair
PC Board Terminals
Power Connection
Terminal Strip
Benshaw supplied terminal
block
Wire Node Symbol may
have terminal block
4
3
2
“ON”
“OFF”
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and
model, per Chart 1. Transformer connections per transformer nameplate connection diagram.
MOVs are used on power stack assemblies for system voltages of 200 through
460 vac (as shown). Resistor/capacitor networks (DVDTs) are used on power
stack assemblies in place of MOVs for a system voltage of 575 vac (not shown).
K3 relay shown in deenergized state. K3 contact will close when power is applied.
K3 contact will open on stop command or system faul
NOTES:
LED status with power applied and prior to run command.
1
Fig. 49 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)
Auxiliary
Bridge Rectifier
Circuit Breaker
Communication
Condenser
Central Processing Unit
Chiller Visual Controller
Current Transformer
Evaporator
Fuse
Ground
Main Supply Power
Control Power Supply
Contactor
Overload Reset
Contactor
Silicone Controller Rectifier
Shunt Trip
Terminal Block
LEGEND
101
Fig. 50 — Typical Wye Delta Free-Standing Starter Wiring Schematic (Low Voltage)
AUX
CB
COMM
COND
CPT
CT
DISCH
DS
EVAP
FU
HPR
ISM
MTR
PFC
PRESS
SCR
ST
STAT
TB
TC
TRAN
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Auxiliary
Circuit Breaker
Communication
Condenser
Control Power Transformer
Current Transformer
Discharge
Disconnect Switch
Evaporator
Fuse
Horsepower
Integrated Starter Module
Motor
Power Factor Contactor
Pressure
Silicone Control Rectifier
Shunt Trip
Status
Terminal Block
Thermostat Cooling
Transformer
Variable Frequency Drive
Starter Vendor Power Wiring
Starter Vendor Control Wiring
Field-Installed Power Wiring
(Supplied by Others)
Field-Installed Control Wiring
(Supplied by Others)
Option — Starter Vendor Wiring
Twisted Pair Wiring By Starter
Vendor
Customer Terminal Connection
102
Fig. 51 — Typical Solid-State Free-Standing Starter Wiring Schematic (Low Voltage)
NOTES:
PFC — Power Factor Contactor
1M CONTACT AUX — Closes when SCR’s are gated (ON)
— Opens when SCR’s are not gated (OFF)
2M CONTACT AUX — Closes when motor is at full voltage (up to speed)
AUX
CB
COMM
COND
CPT
CT
DISCH
DS
EVAP
FU
HPR
ISM
MTR
PFC
PRESS
SCR
ST
STAT
TB
TC
TRAN
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Auxiliary
Circuit Breaker
Communication
Condenser
Control Power Transformer
Current Transformer
Discharge
Disconnect Switch
Evaporator
Fuse
Horsepower
Integrated Starter Module
Motor
Power Factor Contactor
Pressure
Silicone Control Rectifier
Shunt Trip
Status
Terminal Block
Thermostat Cooling
Transformer
Variable Frequency Drive
Starter Vendor Power Wiring
Starter Vendor Control Wiring
Field-Installed Power Wiring
(Supplied by Others)
Field-Installed Control Wiring
(Supplied by Others)
Option — Starter Vendor Wiring
Twisted Pair Wiring By Starter
Vendor
Customer Terminal Connection
LEGEND
Factory Wiring
Field Wiring
Component Terminal
Control Panel Terminal
*Field supplied terminal strip must be located in the control center.
Fig. 52 — Typical COMM1 CCN Communication Wiring for Multiple Chillers
103
INDEX
Abbreviations and Explanations, 5
After Limited Shutdown, 67
Attach to Network Device Control, 45
Automatic Soft Stop Amps Threshold, 48
Auto. Restart After Power Failure, 41
Before Initial Start-Up, 49
Carrier Comfort Network Interface, 59
Capacity Override, 38
Chilled Water Recycle Mode, 49
Chiller Control Module (CCM), 89
Chiller Dehydration, 58
Chiller Familiarization, 5
Chiller Identification Nameplate, 5
Chiller Operating Condition (Check), 66
Chillers with Isolation Valves, 70
Chiller Start-Up (Prepare for), 66
Chillers with Storage Tanks, 71
Chiller Tightness (Check), 49
Cold Weather Operation, 67
Compressor Bearing Maintenance, 75
Compressor Rotor Check, 75
Condenser, 8
Condenser Freeze Prevention, 40
Condenser Pump Control, 40
Control Algorithms Checkout Procedure, 78
Control Panel, 8
Control Panel (Inspect), 73
Control Modules, 88
Controls, 14
Controls (Definitions), 14
Control Test, 63, 78
Cooler, 8
CVC Operation and Menus, 19
Default Screen Freeze, 38
Defective Processor Modules (Replacing), 89
Demand Limit Control Option, 41
Design Set Points, (Input), 60
Display Messages (Checking), 77
Dry Run to Test Start-Up Sequence, 65
Equipment Required, 49
Extended Shutdown, (Preparation for), 67
Extended Shutdown (After), 67
Factory-Mounted Starter (Optional), 8
General Controls Overview, 14
General Maintenance, 72
Heat Exchanger Tubes (Inspect), 75
High Altitude Locations, 63
Hot Gas Bypass (Optional) Algorithm, 41
Ice Build Control, 44
Initial Start-Up, 65
Initial Start-Up (Preparation), 65
Inspect Water Piping, 58
Instruct the Customer Operator, 66
Integrated Starter Module (ISM), 89
Introduction, 4
Job Data Required, 49
Lead/Lag Control, 42
Leak Test Chiller, 50
Local Occupied Schedule (Input), 60
Local Start-Up, 47
Low Discharge Temperature Control, 39
Lubrication Cycle, 8
Lubrication Cycle (Details), 8
Lubrication Cycle (Summary), 8
Lubrication System (Check), 73
Module Operation (Notes), 88
Motor-Compressor, 8
Motor Cooling Cycle, 8
Muffler-Oil Separator, 8
Oil and Oil Filter Changes, 73
Oil Charge, 60
Oil Circuit Valves (Open), 49
Oil Loss Prevention, 9
Oil Pressure and Compressor Stop (Check), 65
Oil Reclaim System, 9
Oil Separator Coalescer, 74
Oil Specification, 74
Oil Sump Temperature Control, 39
Operating Instructions, 66
Operating the Optional Pumpout Unit, 69
Operator Duties, 66
Optional Pumpout Compressor Water Piping (Check), 58
Optional Storage Tank and Pumpout System (Using), 49
Optional Pumpout System Controls and Compressor (Check), 63
Optional Pumpout System Maintenance, 76
Ordering Replacement Chiller Parts, 76
Overview (Troubleshooting Guide), 76
Physical Data, 92
PIC II System Components, 14
PIC II System Functions, 37
Power Up the Controls and Check the Oil Heater, 60
Preparation (Pumpout and Refrigerant Transfer Procedures), 69
Pressure Transducers (Check), 76, 77
Prevent Accidental Start-Up, 66
Pumpout and Refrigerant Transfer Procedures, 69
Ramp Loading, 38
Refrigerant (Adding), 72
Refrigerant (Adjusting the Charge), 72
Refrigerant Charge (Trim), 72
Refrigerant Filter/Drier, 74
Refrigerant Float System (Inspect), 74
Refrigerant Into Chiller (Charge), 64
Refrigerant Leak Rate, 72
Refrigerant Leak Testing, 72
Refrigerant Leak Detector, 40
Refrigerant Properties, 72
Refrigerant (Removing), 72
Refrigerant Strainers,74
Refrigerant Tracer, 49
Refrigeration Cycle, 8
Refrigeration Log, 67
Relief Valves (Check), 58
Relief Valves and Piping (Inspect), 74
Remote Start/Stop Controls, 40
Repair the Leak, Retest, and Apply Standing Vacuum Test, 72
Running System (Check), 66
Safety and Operating Controls (Check Monthly), 73
Safety Considerations, 1
Safety Controls, 38
Safety Shutdown, 49
Scheduled Maintenance, 73
Service Configurations (Input), 60
Service Ontime, 73
Service Operation, 46
Shipping Packaging (Remove), 49
Shunt Trip (Option), 38
Shutdown Sequence, 48
Slide Valve Operation, 67
Slide Valve Principle, 12
Software Configuration, 60
Solid-State Starters, 89
Spare Safety Alarm Contacts, 40
Spare Safety Inputs, 40
Start the Chiller, 66
Starter (Check), 59
Starting Equipment, 12
Starting Equipment (Inspect), 75
Start-Up/Shutdown/Recycle Sequence, 47
Stop the Chiller, 67
Storage Vessel (Optional), 8
System Components, 5
Temperature Sensors (Checking), 77
Test After Service, Repair, or Major Leak, 72
Tighten All Gasketed Joints, 49
Tower Fan Relay Low and High, 40
Troubleshooting Guide, 76
Unit-Mounted Solid-State Starter (Optional), 13
Unit-Mounted Wye-Delta Starter (Optional), 13
Water/Brine Reset, 41
Water Leaks, 75
Water Treatment, 75
Weekly Maintenance, 73
Wiring (Inspect), 58
Copyright 1999 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211
Catalog No. 532-306
Printed in U.S.A.
Form 23XL-3SS
Pg 104
7-99
Replaces: New
Book 2
Tab 5e
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INITIAL START-UP CHECKLIST
FOR 23XL HERMETIC SCREW LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME
ADDRESS
CITY
JOB NO.
MODEL
ZIP
STATE
S/N
DESIGN CONDITIONS
TONS
BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE PRESSURE
OUT
DROP
PASS
SUCTION
TEMPERATURE
COOLER
CONDENSER
COMPRESSOR:
STARTER:
CONDENSER
TEMPERATURE
******
******
Volts
Mfg
RLA
Type
115
OLTA
S/N
230
CONTROL/OIL HEATER:
REFRIGERANT: Type:
Volts
CARRIER OBLIGATIONS:
Assemble . . . . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . .
Dehydrate . . . . . . . . . . . . . . . . . .
Charging . . . . . . . . . . . . . . . . . . .
Operating Instructions
Charge
START-UP TO BE PERFORMED IN ACCORDANCE WITH
JOB DATA REQUIRED:
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . .
2. Machine Assembly, Wiring and Piping Diagrams . . . . . .
3. Starting Equipment Details and Wiring Diagrams . . . . . .
4. Applicable Design Data (see above) . . . . . . . . . . . . . . . .
5. Diagrams and Instructions for Special Controls . . . . . . .
Yes
Yes
Yes
Yes
No
No
No
No
Hrs.
APPROPRIATE MACHINE START-UP INSTRUCTIONS
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
INITIAL MACHINE PRESSURE:
YES
NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
3/4
1/2 Top sight glass
1/4
CHECK OIL LEVEL AND RECORD:
ADD OIL:
Amount:
Yes
No
3/4
1/2 Bottom sight glass
1/4
RECORD PRESSURE DROPS:
CHARGE REFRIGERANT:
Book
Tab
Cooler
Initial Charge
Condenser
Final Charge After Trim
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211
Catalog No. 532-306
Printed in U.S.A.
Form 23XL-3SS
Pg CL-1
7-99
Replaces: New
2
5e
INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
Motor Voltage
Motor(s) Amps
Line Voltages:
Motor
Starter LRA Rating
Controls/Oil Heater
FIELD-INSTALLED STARTERS ONLY:
Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state
starters; disconnect leads to motor and megger the leads.
“PHASE TO PHASE”
MEGGER MOTOR
T1-T2
T1-T3
“PHASE TO GROUND”
T2-T3
T1-G
T2-G
T3-G
10-Second Readings:
60-Second Readings:
Polarization Ratio:
STARTER:
Electro-Mechanical
Motor Load Current Transformer Ratio
Solid-State Overloads
Yes
No
Solid-State
Manufacturer
Serial Number
:
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
PIC II CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
RUN MACHINE:
Do these safeties shut down machine?
Condenser Water Flow
Chilled Water Flow
Pump Interlocks
Yes
Yes
Yes
No
No
No
Yes
INITIAL START:
Line Up All Valves in Accordance With Instruction Manual:
Start Water Pumps and Establish Water Flow
Oil Level OK and Oil Temperature OK
Oil Pressure
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?
Yes*
No
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A: Trim charge and record under Charge Refrigerant Into Chiller section on page 64.
B: Complete any remaining control calibration and record under Controls section (pages 14-47).
C: Take at least two sets of operational log readings and record.
E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
F: Give operating instructions to owner’s operating personnel.
Hours Given:
Hours
G: Call your Carrier factory representative to report chiller start-up.
SIGNATURES:
CARRIER
TECHNICIAN
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-2
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23XL PIC II SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION
Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
RANGE
40 to 100
10 to 120
15 to 120
15 to 60
55 to 105
UNITS
%
DEG F
DEG F
DEG F
DEG F
CVC Software Version Number:
CVC Controller Identification: BUS:
ADDRESS:
CL-3
DEFAULT
100
50.0
60.0
40.0
75
VALUE
23XL PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag
M T W T F S
S
H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 23XL PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S
Day Flag
M T W T F S
S
H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
23XL PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
Day Flag
M T W T F S
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-4
S
H
Occupied
Time
Unoccupied
Time
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23XL PIC II ISM_CONF TABLE CONFIGURATION SHEET
DESCRIPTION
Starter Type
(0=Full, 1=Red, 2=SS/VFD)
Motor Rated Line Voltage
Volt Transformer Ratio: 1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage % Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio: 1
Current % Imbalance
Current Imbalance Time
3 Grnd Fault CT’s? (1=No)
Ground Fault CT Ratio: 1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency-60 Hz? (No=50)
Line Frequency Faulting
RANGE
UNITS
0 to 2
200 to 13200
1 to 35
105 to 115
85 to 95
1 to 10
1 to 10
1 to 10
10 to 5000
100 to 60000
1 to 10
100 to 60000
3 to 1000
5 to 40
1 to 10
0/1
150
1 to 25
1 to 20
1 to 10
0/1
0/1
0/1
DEFAULT
1
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
CL-5
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
VALUE
23XL PIC II OPTIONS TABLE CONFIGURATION SHEET
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Stall/Hot Gas Bypass
Stall Limit/HGBP Option
Select: Stall=0, HGBP=1
Min. Load Point (T1/P1)
Stall/HGBP Delta T1
Stall/HGBP Delta P1
Full Load Point (T2/P2)
Stall/HGBP Delta T2
Stall/HGBP Delta P2
Stall/HGBP Deadband
Stall Protection
Stall Delta % Amps
Stall Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
Refrigerant Leak Option
Refrigerant Leak Alarm mA
Head Pressure Reference
Delta P @ 0% (4 mA)
Delta P @ 100% (20 mA)
Minimum Output
RANGE
0/1
0/1
40 to 100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1
DEFAULT
DSABLE
DSABLE
100
0
0.5 to 20
30 to 170
ˆF
PSI
1.5
150
0.5 to 20
30 to 250
0.5 to 3
ˆF
PSI
ˆF
4
200
1
5 to 20
7 to 10
%
MIN
10
8
0/1
DSABLE/ENABLE
DSABLE
0 to 2
0
0/1
DSABLE/ENABLE
DSABLE
0/1
4 to 20
DSABLE/ENABLE
mA
DSABLE
20
20-30
35-50
0-100
PSI
PSI
%
25
35
0
CL-6
VALUE
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23XL PIC II SETUP1 TABLE CONFIGURATION SHEET
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Comp Discharge Alert
RANGE
150 to 200
150 to 260
125 to 200
UNITS
DEG F
PSI
DEG F
DEFAULT
200
230
200
Chilled Medium
Chilled Water Deadband.
Evap Refrig Trippoint
Refrig Override Delta T
Condenser Freeze Point
0/1
5 to 2.0
0.0 to 40.0
2.0 to 5.0
–20 to 35
WATER/BRINE
ˆF
DEG F
ˆF
DEG F
WATER
1.0
33
3
34
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Water Flow Verify Time
Oil Filter Pressure Alert
Recycle Control
Recycle Restart Delta T
Recycle Shutdown Delta
0.5 to 50.0
0.5 to 50.0
0.5 to 5
1-15
PSI
PSI
MIN
PSI
5.0
5.0
5
3
2.0 to 10.0
0.5 to 4.0
DEG F
DEG F
5
1
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
23XL Model TC Comp?
0 to 4
–40 to 245
0 to 4
–40 to 245
0/1
DEG F
DEG F
NO/YES
CL-7
0
245
0
245
1
VALUE
23XL PIC II SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional Dec Band
Proportional ECW Gain
STATUS
2 to 10
2 to 10
1 to 3
VFD/Slide Valve Control
VFD Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
Manual SV Temp Option
0/1
0.1 to 1.5
1 to 5
20 to 100
50 to 100
0/1
UNITS
DEFAULT
6.5
6.0
2.0
DSABLE/ENABLE
%
%
%
DSABLE/ENABLE
CL-8
DSABLE
0.75
2
0
100
DSABLE
VALUE
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23XL PIC II LEADLAG TABLE CONFIGURATION SHEET
DESDRIPTION
Lead Lag Control
LEAD/LAG Configuration
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG Percent Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Option
STANDBY Percent Capacity
STANDBY Address
RANGE
UNITS
0 to 3
0/1
0/1
25 to 75
1 to 236
2 to 60
2 to 60
2 to 30
0/1
25 to 75
1 to 236
DEFAULT
0
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
CL-9
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
VALUE
23XL PIC II RAMP_DEM TABLE CONFIGURATION SHEET
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Motor Load Ramp % Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Motor Rated Kilowatts
Demand Watts Interval
RANGE
UNITS
DEFAULT
0/1
1
0/1
0
5 to 20
3 to 15
40 to 100
0/1
50 to 9999
5 to 60
%
%
DSABLE/ENABLE
kW
MIN
VALUE
10
10
40
DSABLE
145
15
23XL PIC II TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp (No Reset)
Remote Temp (Full Reset)
Degrees Reset
RESET TYPE 3
CHW Delta T (No Reset)
CHW Delta T (Full Reset)
Degrees Reset
Select/Enable Reset Type
RANGE
UNITS
DEFAULT
0/1
2 to 10
DSABLE/ENABLE
ˆF
DSABLE
3
–30 to 30
ˆF
10
–40 to 245
–40 to 245
–30 to 30
DEG F
DEG F
ˆF
85
65
10
0 to 15
0 to 15
–30 to 30
ˆF
ˆF
ˆF
10
0
5
0 to 3
0
CL-10
VALUE
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23XL BROADCAST (BRODEF) CONFIGURATION SHEET
DESCRIPTION
Time Broadcast Enable
Daylight Savings
Start Month
Start Day of Week
Start Week
Start Time
Start Advance
Stop Month
Stop Day of Week
Stop Week
Stop Time
Stop Back
RANGE
0/1
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
UNITS
DSABLE/ENABLE
HH:MM
MIN
MIN
CL-11
DEFAULT
DSABLE
4
7
3
02:00
60
10
7
3
02:00
60
VALUE
Book
Tab
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211
Catalog No. 532-306
Printed in U.S.A.
Form 23XL-3SS
Pg CL-12
7-99
Replaces: New
2
5e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
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Copyright 1999 Carrier Corporation